Redundant Trace Fuse for a Conformal Wearable Battery

ABSTRACT

A housing of a conformal wearable battery (CWB) encloses a plurality of battery cells arranged in a grid-like pattern and electrically connected to a printed circuit board (PCB). The PCB includes an electrical connection pad that is electrically coupled to a positive terminal of a battery cell of the plurality of battery cells and a positive conductive region receiving electrical energy from one or more of the plurality of battery cells. A redundant trace fuse circuit is formed on the PCB to facilitate electrical connection of the electrical connection pad and the positive conductive region. The redundant trace fuse circuit includes a first fusible link for electrically connecting the first electrical connection pad to the positive conductive region and a second fusible link that is selectively enabled to electrically connect the first electrical connection pad to the positive conductive region when the first fusible link is inoperative.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.17/085,928 (Attorney Docket No. 009231.00112), entitled “FlexibleBattery Matrix for a Conformal Wearable Battery,” which is acontinuation of U.S. patent application Ser. No. 17/085,864 (AttorneyDocket No. 009231.00111) entitled “Flexible Battery Matrix for aConformal Wearable Battery,” filed on Oct. 30, 2020 and issued on Mar.16, 2021 as U.S. Pat. No. 10,950,913, which is a continuation-in-part ofU.S. patent application Ser. No. 17/038,287 (Attorney Docket No.009231.00108), entitled “Flexible Circuit Board for a Conformal WearableBattery” filed on Sep. 30, 2020 and that issued on Jul. 13, 2021 as U.S.Pat. No. 11,064,604. U.S. application Ser. No. 17/085,928 is also acontinuation-in-part of U.S. patent application Ser. No. 17/038,287.This application is also a continuation-in-part of U.S. patentapplication Ser. No. 17/202,109 (Attorney Docket No. 009231.00113),entitled “Conformal Wearable Battery” filed on Mar. 15, 2021, which is acontinuation-in-part of U.S. patent application Ser. No. 17/038,287(Attorney Docket No. 009231.00108), entitled “Flexible Circuit Board fora Conformal Wearable Battery” filed on Sep. 30, 2020 and that issued onJul. 13, 2021 as U.S. Pat. No. 11,064,604. U.S. patent application Ser.No. 17/202,109 is also a continuation-in-part of U.S. application No.17/085,873 (Attorney Docket No. 009231.00107) filed on Oct. 30, 2020,entitled “Housing for a Conformal Wearable Battery,” which is acontinuation-in-part of U.S. patent application Ser. No. 17/038,287filed on Sep. 30, 2020. U.S. patent application Ser. No. 17/202,109 isalso a continuation-in-part of U.S. application Ser. No. 17/086,132(Attorney Docket No. 009231.00110) filed on Oct. 30, 2020 and thatissued on Mar. 16, 2021 as U.S. Pat. No. 10,950,913, entitled “ImpactAbsorbing Member for a Conformal Wearable Battery,” which is acontinuation-in-part of U.S. patent application Ser. No. 17/038,287filed on Sep. 30, 2020. U.S. patent application Ser. No. 17/202,109 isalso a continuation-in-part of U.S. application Ser. No. 17/085,864(Attorney Docket No. 009231.00111) filed on Oct. 30, 2020 and thatissued on Apr. 13, 2021 as U.S. Pat. No. 10,980,116, entitled “FlexibleBattery Matrix for a Conformal Wearable Battery,” which is acontinuation-in-part of U.S. patent application Ser. No. 17/038,287filed on Sep. 30, 2020. U.S. patent application Ser. No. 17/202,109 isalso a continuation-in-part of U.S. application Ser. No. 17/085,928(Attorney Docket No. 009231.00112), entitled “Flexible Battery Matrixfor a Conformal Wearable Battery,” which is a continuation of U.S.patent application Ser. No. 17/085,864 filed on Oct. 30, 2020, which isa continuation-in-part of U.S. patent application Ser. No. 17/038,287filed on Sep. 30, 2020. All of the above listed applications are hereinincorporated by reference in their entirety.

FIELD

Aspects described herein generally relate to electrical power storagesystems. More specifically, aspects of this disclosure relate toredundant trace fuse configurations for battery cell connections to aprinted circuit board, sealed housings for a matrix of battery cells, aflexible printed circuit boards providing conductive paths for a matrixof battery cells, impact absorbing members to absorb or reduce shock andvibration forces seen by the electronic members for a portableelectrical power storage system, and to flexible printed circuit boardsproviding conductive paths for a matrix of battery cells.

BACKGROUND

Batteries may come in different shapes and sizes depending on theirintended usage. Some batteries may be arranged as packages of batterycells that are assembled together to provide a predetermined poweroutput. These battery packages may be arranged in a durable and sealedhousing to protect the batteries from damage. In some instances, thebattery packages may be desired to flex or bend to accommodate theirintended usage.

In addition, portable battery systems may be utilized to provide mobileand/or remote location electrical power. Integrated communicationsequipment and/or weapons gear utilized, for example, by law enforcementand/or military personnel requires increasingly high levels of powerstorage carried proximate the user's body. Methods of increasing powerstorage capability in a device, such as a conformal wearable battery(CWB) is to include additional battery cells and/or use larger batterycells. However, these solutions may unacceptably increase the sizeand/or weight of the resulting systems, reducing mobility.

As such, a need has been recognized within the mobile electrical powerstorage industry for increasing power capacity while improving anoverall user safety of these systems, simultaneously reducing their sizeand weight, while improving manufacturability of individual CWB units.

SUMMARY

Aspects of the disclosure provide solutions that address and overcometechnical problems associated with redundant trace fuse groupselectrically connecting an electrical connection pad to a positivecharge bus or negative charge bus of a printed circuit board.

Additional aspects of this disclosure may relate to redundant trace fuseconfigurations comprising at least two trace fuses formed into circuitryof a flexible printed circuit board (PCB). A housing of a conformalwearable battery (CWB) encloses a plurality of battery cells arranged ina grid-like pattern and electrically connected to a flexible printedcircuit board (PCB). The flexible PCB includes an electrical connectionpad that is electrically coupled to a positive terminal of a batterycell of the plurality of battery cells and a positive conductive regionreceiving electrical energy from one or more of the plurality of batterycells. A redundant trace fuse circuit is formed on the flexible PCB tofacilitate electrical connection of the electrical connection pad andthe positive conductive region. The redundant trace fuse circuitincludes a first fusible link for electrically connecting the firstelectrical connection pad to the positive conductive region and a secondfusible link that is selectively enabled to electrically connect thefirst electrical connection pad to the positive conductive region whenthe first fusible link is inoperative.

Additional aspects of this disclosure may relate to a conformal wearablebattery with a redundant trace fuse circuit including a plurality ofbattery cells arranged in a grid-like pattern, a housing with aninterior cavity that receives the plurality of battery cells, and aprinted circuit board. In some cases, each battery cell of the pluralityof battery cells comprises a positive terminal and a negative terminalto provide electricity through a transfer of electrons between thepositive terminal and negative terminal. The printed circuit board mayinclude a first electrical connection pad coupled to a positive terminalof a battery cell of the plurality of battery cells, a positiveconductive region receiving electrical energy via positive terminals ofone or more of the plurality of battery cells, and a first redundanttrace fuse circuit. The redundant trance fuse circuit may include afirst fusible link electrically connecting the first electricalconnection pad to the positive conductive region and a second fusiblelink that is selectively enabled to electrically connect the firstelectrical connection pad to the positive conductive region.

Additional aspects of this disclosure may relate to a conformal wearablebattery with a printed circuit board including a second electricalconnection pad coupled to a negative terminal of the battery cell of theplurality of battery cells, a negative conductive region receivingelectrical energy via negative terminals of one or more of the pluralityof battery cells, and a second redundant trace fuse circuit including athird fusible link electrically connecting the second electricalconnection pad to the negative conductive region and a fourth fusiblelink to selectively electrically connect the second electricalconnection pad to the negative conductive region. In some cases, thefirst redundant trace fuse circuit includes a plurality of conductivepaths to connect the first electrical connection pad to the positiveconductive region, where each of the plurality of conductive paths maybe connected independently from the other. In some cases, a firstconductive path of the plurality of conductive paths may be a fuseelement and a first pair of electrically separated conductive pads,wherein the fuse element is enabled via connection of a jumper betweenthe first pair of electrically separated conductive pads. In some cases,a first conductive path of the plurality of conductive paths may be apair of electrically separated conductive pads, where the firstconductive path is enabled via connection of an external fuse component.

Additional aspects of this disclosure may relate to a printed circuitboard, including a pair of electrical connection pads including a firstelectrical connection pad that may be coupled to a positive terminal ofa battery cell of a plurality of battery cells, and a second electricalconnection pad that may be coupled to a negative terminal of the batterycell of the plurality of battery cells. The printed circuit board mayinclude a positive conductive region receiving electrical energy viapositive terminals of one or more of the plurality of battery cells anda negative conductive region receiving electrical energy via negativeterminals of one or more of the plurality of battery cells. The printedcircuit board may include a plurality of first redundant trace fusecircuits, where each trace fuse circuit may include a first fusible linkthat electrically connects the first electrical connection pad to thepositive conductive region and a second fusible link that is selectivelyenabled to electrically connect the first electrical connection pad tothe positive conductive region.

Additional aspects of this disclosure may relate to a printed circuitboard the may include a second redundant trace fuse circuit including athird fusible link electrically connecting the second electricalconnection pad to the negative conductive region and a fourth fusiblelink to selectively electrically connect the second electricalconnection pad to the negative conductive region. In some cases, thesecond fusible link comprises a plurality of conductive paths to connectthe first electrical connection pad to the positive conductive region,wherein each of the plurality of conductive paths are connectedindependently from the other. In some cases, a first conductive path ofthe plurality of conductive paths may include a fuse element and a firstpair of electrically separated conductive pads, where the fuse elementmay be enabled via connection of a jumper between the first pair ofelectrically separated conductive pads. In some cases, a firstconductive path of the plurality of conductive paths may include a pairof electrically separated conductive pads, where the first conductivepath may be enabled via connection of an external fuse component.

Additional aspects of this disclosure may relate to method includingforming a first electrical connection between a first electricalconnection pad and a first battery terminal, measuring, after forming(e.g., creating) the first electrical connection, continuity of a firstelectrical path between the first electrical connection pad and a firstconductive region of a printed circuit board, wherein the firstelectrical path comprises a first trace fuse component formed on theprinted circuit board, and selectively enabling, based on a measureddiscontinuity in the first electrical path, a second electricalconnection between the first electrical connection pad and the firstconductive region, wherein the second electrical connection comprises asecond fuse component. In some cases, forming the second electricalconnection path may include electrically connecting a second fusecomponent using a conductive shunt component. In some cases, the secondfuse component may include a second trace fuse component formed on theprinted circuit board. In some cases, the method may include measuring,after forming the second electrical connection, continuity of a secondelectrical path between the first electrical connection pad and thefirst conductive region of the printed circuit board, where the secondelectrical path may include a second trace fuse component formed on theprinted circuit board, selectively enabling, based on a measureddiscontinuity in the second electrical path, a third electrical pathbetween the first electrical connection pad and the first conductiveregion, where the third electrical path comprises a third fusecomponent. In some cases, the third fuse component may include one of athird trace fuse component or a pair of secondary electrical connectionpads formed on the printed circuit board to receive an external fusecomponent. In some cases, the method may include electrically connectinga fuse component to a pair of secondary electrical connection padsformed on the printed circuit board. In some cases, forming the firstelectrical connection between the first electrical connection pad andthe first battery terminal may include heating one or both of the firstelectrical connection pad and the first battery terminal and where theheating one or both of the first electrical connection pad and the firstbattery terminal causes the discontinuity in the first electrical path.In some cases, the method may include inserting through a pair ofcutouts in the printed circuit board, the first battery terminal and asecond battery terminal of a first battery cell, where the first batterycell may be positioned adjacent a first side of the printed circuitboard and the first electrical connection pad and a second electricalconnection pad are on a second side of the printed circuit boardopposite the first side.

In some cases, the method may further include forming a secondelectrical connection between a second electrical connection pad and thesecond battery terminal measuring, after forming the second electricalconnection, continuity of a fourth electrical path between the secondelectrical connection pad and a second conductive region of a printedcircuit board, where the second electrical path comprises a fourth tracefuse component formed on the printed circuit board, and selectivelyenabling, based on a measured discontinuity in the fourth electricalpath, a fifth electrical connection between the second electricalconnection pad and the second conductive region, where the fifthelectrical connection comprises a fifth fuse component. In some cases,the method may further include connecting, based on a successfulconnection of the first battery cell to the printed circuit board, asecond battery cell to the printed circuit board by forming a sixthelectrical connection between a third electrical connection pad and athird battery terminal comprising an anode of the second battery cellmeasuring, after forming the sixth electrical connection, continuity ofa sixth electrical path between the third electrical connection pad anda first conductive region of a printed circuit board, where the sixthelectrical path comprises a sixth trace fuse component formed on theprinted circuit board, and selectively enabling, based on a measureddiscontinuity in the third electrical path, a seventh electricalconnection between the third electrical connection pad and the firstconductive region, were the seventh electrical connection comprises aseventh fuse component.

Additional aspects of this disclosure may relate to a method ofassembling a printed circuit board assembly that may include (a)electrically connecting, via an application of heat energy, an anode tabof a battery cell to a first electrical connection pad formed in aprinted circuit board and a cathode tab of the battery cell to a secondelectrical connection pad formed in the printed circuit board, whereinthe first electrical connection pad is electrically connected to a firstcharge bus of the printed circuit board via a first trace fuse of afirst redundant trace fuse assembly and the second electrical connectionpad is electrically connected to a second charge bus of the printedcircuit board via a second trace fuse of a second redundant trace fuseassembly and wherein the first trace fuse assembly and the second tracefuse assembly are formed in the printed circuit board, (b) determiningwhether one of the first trace fuse or the second trace fuse is in opencircuit condition, (c) selectively enabling, based on an indication thatthe first trace fuse is an open circuit condition, a third trace fuse ofthe first trace fuse assembly (d) selectively enabling, based on anindication that the second trace fuse is an open circuit condition, afourth trace fuse of the second trace fuse assembly (e) determiningwhether one of the third trace fuse or the fourth trace fuse is in opencircuit condition, (f) repeating steps (a)-(e), based on an indicationthat the anode tab is electrically connected to the first charge bus viathe first redundant trace fuse assembly and the cathode tab iselectrically connected to the second charge bus via the second redundanttrace fuse assembly, to electrically connect a second battery cell tothe printed circuit board; and (g) discontinuing, based on an indicationthat at least one of the third trace fuse or the fourth trace fuse is inan open circuit condition, assembly of the printed circuit boardassembly.

Additional aspects of this disclosure may relate to a conformal wearablebattery that includes a plurality of battery cells arranged in agrid-like pattern, where the plurality of battery cells have a positiveterminal and a negative terminal to provide electricity through atransfer of electrons between the positive terminal and negativeterminal, a housing with an interior cavity that receives the pluralityof battery cells, a conductive region coupled to one or more of thepositive terminal and the negative terminal, where the electricity isprovided from one or more of the plurality of battery cells to theconductive region, and a contact component having a front portion and arear portion, where the contact component comprises an electricallyconductive material. The front portion of the contact component mayinclude an outward facing surface and a perimeter region surrounding theoutward facing surface, where the outward facing surface may beaccessible from outside of the interior cavity of the housing and therear portion may have an inward facing surface. The contact componentmay be connected to the conductive region. The perimeter region of theoutward facing surface of the contact component may be secured to thehousing forming a sealed edge to prevent ingress of liquid into theinterior cavity. The conformal wearable battery may also include acontact carrier that encases the rear portion of the contact component,where the contact carrier is also secured to the housing. The contactcarrier may be secured to the housing between a rear surface of asidewall of the housing and a rear flange that is spaced rearward of therear surface. The housing may include a first plug that extends from therear surface of the sidewall through an opening in the contact carrierto the rear flange of the housing. The electrically conductive materialof the contact component may be formed from at least one materialselected from brass, gold, copper, silver, aluminum, steel, or acombination thereof. The perimeter region may include a groove, and therear portion may include a textured region and a threaded femaleelement. The textured region may include a plurality of angled gearteeth. The contact component may also include an opening that receives aconductive element to create a connection between the conductive regionand the contact component.

Still other aspects of this disclosure may relate to a conformalwearable battery that includes: (a) a plurality of battery cellscomprising a positive terminal and a negative terminal to provideelectricity through a transfer of electrons between the positiveterminal and negative terminal; (b) a housing that includes a firstshell and a second shell, where the first shell may connect to thesecond shell to form an interior cavity that receives the plurality ofbattery cells; (c) a conductive region coupled to one or more of thepositive terminal and the negative terminal, where the electricity isprovided from one or more of the plurality of battery cells to theconductive region; (d) a first contact carrier that secures a firstelectrically conductive contact component, where the first contactcarrier is secured to the first shell; and (f) the first contactcomponent having a front portion and a rear portion. The front portionof the first contact component may include an outward facing surface anda perimeter region surrounding the outward facing surface, where theoutward facing surface is accessible from outside of the interior cavityof the housing. The first contact component is connected to theconductive region. The first contact carrier may be secured to thehousing between a first rear surface of a first sidewall of the firstshell and a first rear flange that is spaced rearward of the first rearsurface. A first plug may extend from the first rear surface of thefirst sidewall through an opening in the first contact carrier to thefirst rear flange of the first shell, where the first plug, the firstrear flange, and the first sidewall may be a single unitary member. Asidewall of the first shell may surround the perimeter region of thefirst contact component, and the first contact carrier may surround atextured region of the first contact component. The first rear flangemay include an opening to allow access to an inward facing surface ofthe first contact component. A connector plate configured to receive aconnector may be secured between a second rear surface of a secondsidewall of the first shell and a second rear flange. In addition, asecond plug may extend from the second rear surface through an openingin the connector plate to the second rear flange. The CWB may alsoinclude a second contact carrier, where the first contact carriersecures the first contact component and a second electrically conductivecontact component. The second contact carrier may secure a thirdelectrically conductive contact component and a fourth electricallyconductive contact component.

Other aspects of this disclosure may relate to a system that includes:(a) an electronic component to provide an electrical signal, wherein theelectronic component comprises a plurality of battery cells; (b) ahousing that includes an interior cavity that receives the electroniccomponent; (c) a conductive region coupled to the electronic component,where the electrical signal is provided from the electronic component tothe conductive region; and (d) an electrically conductive contactcomponent having a front portion and a rear portion. The front portionof the contact component may include an outward facing surface and aperimeter region surrounding the outward facing surface. The outwardfacing surface may be accessible from outside of the interior cavity ofthe housing, and the rear portion may have an inward facing surface. Thecontact component may be connected with the conductive region. The frontportion may be partially encased by a first material that forms asidewall of the housing, and the rear portion may be partially encasedby a second material, where the first material may have a lowerdurometer than the second material. The electronic component maycomprise a battery-charging controller and a computing processor. Theperimeter region of the contact component may include a groove, and therear portion of the contact component may include a textured region anda threaded female element. The contact component may include a threadedopening that receives a conductive element to create a direct connectionbetween the conductive region and the contact component. The rearportion of the contact component may be secured to a contact carrierthat is formed from the second material.

Yet still other aspects of this disclosure may relate to a conformalwearable battery that includes: (a) a plurality of battery cellsarranged in a grid-like pattern, where the plurality of battery cellsincludes a positive terminal and a negative terminal to provideelectricity through a transfer of electrons between the positiveterminal and negative terminal; and (b) a housing that includes: (1) afirst shell formed from a first member having a first plurality of rigidregions and a second member that has a first flexible region locatedbetween a first rigid region and a second rigid region of the firstplurality of rigid regions, where the first shell includes a front wallwith an outward facing surface formed from outward facing surfaces ofthe first plurality of rigid regions and an outward facing surface ofthe second member, and (2) a second shell attached to the first shell,wherein the second shell includes a third member having a secondplurality of rigid regions and a fourth member that has a secondflexible region located between a first rigid region and a second rigidregion of the second plurality of rigid regions. The second shell mayhave an outward facing surface formed from outward facing surfaces ofthe second plurality of rigid regions and an outward facing surface ofthe second member, where the first shell may connect to the second shellto form an interior cavity that receives the plurality of battery cells.The first member may be formed from a first material, and the secondmember may be formed from a second material, where the first materialhas a hardness that is greater than a hardness of the second material.The third member may be formed from the first material, and the fourthmember may be formed from the second material. The first material may beformed from a polycarbonate, and the second material may be formed froma thermoplastic elastomer. The second member may be molded onto thefirst member to form the first shell. Additionally, the first rigidregion of the first plurality of rigid regions may include a firstoutward facing surface, a first inward facing surface, and a first edgeregion along a majority of a perimeter of the first rigid regionextending between the first outward facing surface and the first inwardfacing surface. The first edge region may include a first edge surfaceand a second edge surface, where the first edge surface and the secondedge surface extend in different directions. The second member may havea second edge region that has a complementary structure to the firstedge region such that the first member and the second member aresubstantially coplanar on adjacent surfaces of the first edge region.

Still additional aspects of this disclosure may relate to a housing fora plurality of battery cells arranged in a grid-like pattern, where thehousing includes: (a) a first shell having a first member having aplurality of rigid regions and a second member that has a flexibleregion located between a first rigid region and a second rigid region ofthe plurality of rigid regions, where a first wall of the first shellhas an outward facing surface formed from outward facing surfaces of theplurality of rigid regions and an outward facing surface of the secondmember and (b) a second shell attached to the first shell forming aninterior cavity between the first shell and the second shell. The firstmember may be formed as a unitary member, and the second member may bemolded onto the first member. In addition, the first member may beformed from a first material, and the second member may be formed from asecond material. The first material may have a first hardness, and thesecond material may have a second hardness, where the first hardness maybe greater than the second hardness. The plurality of rigid regions maybe arranged in an array with the plurality of rigid regions in both ahorizontal direction and a vertical direction that correspond to thegrid-like pattern of the plurality of battery cells. Each rigid regionof the plurality of rigid regions may be spaced apart from an adjacentrigid region and is connected to the adjacent rigid region by a channel.The channel may act as a living hinge, and the channel may have athickness that is less than a thickness of the first rigid region. Thefirst rigid region of the plurality of rigid regions may include a firstoutward facing surface, a first inward facing surface, and a first edgeregion along a majority of a perimeter of the first rigid regionextending between the first outward facing surface and the first inwardfacing surface. The first edge region may include a first edge surfacethat extends substantially perpendicular to the first outward facingsurface and a second edge surface has a portion that extendssubstantially perpendicular to the first edge surface. The second edgesurface may include a curved portion. A thickness of the first rigidregion may be substantially the same as a thickness of the flexibleregion, where the thickness of the first rigid region may be measured ata center of the first rigid region and the thickness of the flexibleregion may be measured at a location adjacent a first edge region of thefirst rigid region. The second shell may include a third member having asecond plurality of rigid regions and a fourth member that has a secondflexible region located between a first rigid region and a second rigidregion of the second plurality of rigid regions. A first wall of thesecond shell may have an outward facing surface formed from outwardfacing surfaces of the plurality of rigid regions and an outward facingsurface of the second member. The second member may include a pluralityof horizontal grooves and a plurality of vertical grooves.

Additional aspects of this disclosure may relate to a housing for aplurality of battery cells arranged in a grid-like pattern, where thehousing includes a first shell having a first member having a pluralityof rigid regions and a second member that has a flexible region locatedbetween a first rigid region and a second rigid region of the pluralityof rigid regions, and wherein a first wall of the first shell has anoutward facing surface formed from outward facing surfaces of theplurality of rigid regions and an outward facing surface of the secondmember, where the plurality of rigid regions are arranged in an arraywith the plurality of rigid regions in both a horizontal direction and avertical direction that correspond to the grid-like pattern of theplurality of battery cells and each rigid region of the plurality ofrigid regions are spaced apart from an adjacent rigid region and isconnected to the adjacent rigid region by a channel. The first membermay be formed as a unitary member, and the second member may be moldedonto the first member. The first member may be formed from a firstmaterial, and the second member may be formed from a second material.The first material may have a first hardness, and the second materialmay have a second hardness, where the first hardness is greater than thesecond hardness.

Aspects of the disclosure provide solutions that address and overcometechnical problems associated with minimizing size of a portable batterysystem (e.g. a conformal wearable battery system).

A flexible printed circuit board assembly (PCBA) for a conformalwearable battery (CBB) includes attachment sections for a plurality ofbattery cells that are arranged in a grid-like pattern on a same side ofthe flexible PCBA. The flexible PCBA is configured to fold along a bendaxis so that the flexible PCBA is folded approximately in half. Toreduce mechanical stresses placed on the flexible PCBA when folding theflexible PCBA along the bend axis, the flexible PCBA includes aplurality of cut-outs dispersed along the bend axis and parallel toadjacent battery cells. The CWB is configured to flex during use. Theflexible PCBA includes a plurality of cut-outs disposed perpendicular tothe bend axis, between adjacent rows of battery cells, and on the bendaxis to relieve mechanical stresses applied to a bent portion of theflexible PCBA when the CWB is flexed during use.

Aspects of the disclosure may relate to a conformal wearable batterythat may include a plurality of battery cells and a flexible printedcircuit board assembly (PCBA). The flexible PCBA may include a pluralityof physical connection sections disposed in a grid like pattern, whereineach of the plurality of battery cells is physically affixed to theflexible PCBA at a corresponding physical connection section of theplurality of physical connection sections, a bend axis disposed betweentwo parallel physical connection sections, wherein the bend axisfacilitates folding of the flexible PCBA in half. Additionally, theflexible PCBA may include a plurality of first cut-outs disposed alongthe bend axis, wherein each first cut-out of the plurality of firstcut-outs is disposed parallel to the bend axis and a plurality of secondcut-outs disposed across the bend axis, wherein each second cut-out ofthe plurality of second cut-outs are disposed perpendicular to the bendaxis.

Aspects of the disclosure may relate to a conformal wearable batterythat may include a first plurality of electrical connections eachconnecting a cathode of a corresponding battery cell of the plurality ofbattery cells and second plurality of electrical connections eachconnecting an anode of the corresponding battery cell of the pluralityof battery cells to electrical conductors of the flexible printedcircuit board assembly.

Aspects of the disclosure may relate to a conformal wearable batterythat may include a bend axis where the bend axis comprises a centerportion of the grid like pattern of the physical connection sections.

Aspects of the disclosure may relate to a conformal wearable batterythat may include the plurality of cut-outs where each first cut-out ofthe plurality of first cut-outs is rectangular-shaped, and where alonger edge of each first cut-out is disposed parallel to the bend axis.The conformal wearable battery may include a first cut-out where eachcorner of each first cut-out of the plurality of first cut-outs isrounded and/or where each second cut-out of the plurality of secondcut-outs comprises a first semi-circular section, a second semi-circularsection and a rectangular section. The flexible PCBA may include a firstcut-out where the rectangular section is disposed between the firstsemi-circular section and the second semi-circular section and/or wherethe rectangular section is disposed laterally across the bend axis,wherein a mid-point of the rectangular section is located near the bendaxis.

Aspects of the disclosure may relate to a conformal wearable batterythat may have each of the plurality of battery cells physically attachedto a first side of the flexible PCBA and/or where the plurality ofbattery cells is disposed on an outside surface of the flexible PCBAwhen the flexible PCBA is in a folded configuration.

Aspects of the disclosure may relate to a conformal wearable batterythat may further include a sealed flexible housing wherein the flexiblePCBA is disposed within an interior cavity of the sealed flexiblehousing and wherein the flexible PCBA is in a folded configuration.

Aspects of the disclosure may relate to a system that may include aplurality of battery cell modules and a flexible printed circuit boardassembly (PCBA). The flexible PCBA includes a plurality of battery cellconnection sections disposed in a grid-like pattern along a firstsurface of the flexible PCBA, a bend axis configured to divide theflexible PCBA in half when the flexible PCBA is in a foldedconfiguration, and a plurality of cut-outs disposed along the bend axis,wherein each of the plurality of cut-outs reduce a bending force placedon the flexible PCBA when a flexing force is applied to the flexiblePCBA. The system may include the plurality of cut-outs comprises aplurality of first cut-outs having a first shape, and a second pluralityof cut-outs having a second shape. In some cases, the first shapecomprises a substantially rectangular shape having rounded cornersand/or the second shape comprises at least one semi-circular section anda rectangular section. In some cases, the second shape comprises arectangular section disposed across the bend axis and a firstsemi-circular section disposed at an end of the rectangular section on afirst side of the bend axis and a second semi-circular section disposedat an opposite end of the rectangular section and on an opposite side ofthe bend axis. In some cases, a first plurality of cut-outs of theplurality of cut-outs are located near an approximate mid-point of abattery cell module and/or where a portion of the plurality of cut-outsis disposed on a bend line that is perpendicular to the bend axis andbetween two adjacent battery cell modules

Aspects of the disclosure may relate to a flexible printed circuit boardassembly (PCBA) that may include a plurality of battery modulesphysically affixed to the flexible PCBA, wherein the plurality ofbattery modules are arranged in a grid-like pattern, a bend axis near anapproximate mid-point of the flexible PCBA, wherein bending the flexiblePCBA along the bend axis folds the flexible PCBA in half, and aplurality of cut-outs disposed along the bend axis, wherein the cutoutsreduce a force exerted on the flexible PCBA along the bend axis when theflexible circuit board is flexed. In some cases, the plurality ofcut-outs disposed along the bend axis comprise a plurality of firstcut-outs having a first shape and a plurality of second cut-outs havinga second shape and wherein the plurality of first cut-outs are disposedalong a flexible portion of the flexible PCBA between adjacent rows ofthe grid-like pattern that are perpendicular to the bend axis and theplurality of second cut-outs are disposed between adjacent batterymodules in columns of the grid-like pattern, wherein the columns are onopposite sides of the bend axis.

Some aspects of this disclosure may relate to a conformal wearablebattery (CWB) that includes: (a) a plurality of non-cylindrical shapedbattery polymer cells; (b) a flexible printed circuit board (PCB) with aplurality of physical connection sections disposed in a grid likepattern, where each of the plurality of battery cells is physicallyaffixed to the flexible PCB at a corresponding physical connectionsection of the plurality of physical connection sections and a bend axisthat facilitates folding of the flexible PCB to form an upper portion ofthe flexible PCB and a lower portion of the flexible PCB; (c) avisco-elastic central shock-absorbing member positioned between theupper portion and the lower portion of the flexible PCB preventing theupper portion from contacting the lower portion, where the centralshock-absorbing member electrically insulates the upper portion from thelower portion; and (d) a flexible housing that includes an internalcavity that receives the plurality of battery cells, the flexible PCB,and the central shock-absorbing member. The CWB may also include aplurality of visco-elastic battery cell shock-absorbing members, whereeach battery cell shock-absorbing member of the plurality of batterycell shock-absorbing members being individually attached to an outwardfacing surface of each battery cell. Each battery cell shock-absorbingmember may have an opening that is substantially aligned with a centerof a pouch cell portion of each battery cell. The opening may have anarea that is within a range of 30 percent and 70 percent of an area of afront surface of the battery cell shock-absorbing member, where the areaof the front surface is defined as the area of the front surface that isfree of the opening. At least one battery cell shock-absorbing member ofthe plurality of shock-absorbing members may contact an interior surfaceof the housing. A thickness of the central shock-absorbing member may besubstantially the same as a thickness of one of the plurality of batterycell shock-absorbing members. In some examples, a thickness of thecentral shock-absorbing member may be within a range of 1.2 and 1.4times a thickness of one of the plurality of battery cellshock-absorbing members. The central shock-absorbing member may becontinuous and extend at least 90 percent of a width of the upperportion of the flexible PCB. A thickness of the central shock-absorbingmember may be within a range of 2 percent and 5 percent of a thicknessof the conformal wearable battery, where the thickness of the conformalwearable battery is defined as a distance from an outermost outwardfacing surface of an upper housing member to an outermost outward facingsurface of a lower housing member. The central shock-absorbing membermay be the same material as a battery cell shock-absorbing member of theplurality of battery cell shock-absorbing members, and where the centralshock-absorbing member comprises polyurethane.

Other aspects of this disclosure may relate to a conformal wearablebattery that includes (a) a plurality of battery cells; (b) a flexibleprinted circuit board (PCB) that includes a plurality of physicalconnection sections, where each of the plurality of battery cells isphysically affixed to the flexible PCB at a corresponding physicalconnection section of the plurality of physical connection sections anda bend axis that facilitates folding of the flexible PCB to form anupper portion of the flexible PCB and a lower portion of the flexiblePCB; (c) a plurality of battery cell shock-attenuating members, eachbattery cell shock-attenuating member of the plurality of battery cellshock-attenuating members being individually attached to an outwardfacing surface of each battery cell, where each battery cellshock-attenuating member is a foam member and has an opening thatextends through the battery cell shock-attenuating member; and (d) ahousing that includes an upper housing member, a lower housing member,and an internal cavity, wherein the internal cavity that receives theplurality of battery cells, the flexible PCB, and the plurality ofbattery cell shock-attenuating members. A first battery cellshock-attenuating member of the plurality of battery cellshock-attenuating members contacts an interior surface of the lowerhousing member and a second battery cell shock-attenuating member of theplurality of battery cell shock-attenuating members contacts an interiorsurface of the upper housing member. When a battery cell of theplurality of battery cells increases in volume, one of a battery cellshock-attenuating member of the plurality of shock-attenuating membersis compressed. A thickness of a battery cell shock-attenuating member ofthe plurality of battery cell shock-attenuating members may be within arange of 4 percent and 12 percent of a thickness of a battery cell ofthe plurality of battery cells. The opening of the plurality of batterycell shock-attenuating members may have an oval shape. The CWB may alsoinclude a central shock-attenuating member, where the centralshock-attenuating member may be positioned between the upper portion andthe lower portion of the flexible PCB to prevent the upper portion fromcontacting the lower portion. The central shock-attenuating member mayelectrically insulate the upper portion from the lower portion. Inaddition, a thickness of the central shock-attenuating member may besubstantially the same as a thickness of a battery cellshock-attenuating member of the plurality of battery cellshock-attenuating members.

Still additional aspects of this disclosure may relate to a system thatincludes: (a) a plurality of battery cells; (b) a flexible printedcircuit board (PCB) that has a plurality of physical connectionsections, where each of the plurality of battery cells may be physicallyaffixed to the flexible PCB at a corresponding physical connectionsection of the plurality of physical connection sections and a bend axisthat may facilitate folding of the flexible PCB to form an upper portionof the flexible PCB and a lower portion of the flexible PCB; (c) acentral shock-attenuating member formed from a polymeric foam material,where the central shock-attenuating member may be positioned between theupper portion and the lower portion that prevents the upper portion ofthe flexible PCB from contacting the lower portion of the flexible PCB;(d) a plurality of battery cell shock-attenuating members formed from apolymeric foam material, where each battery cell shock-attenuatingmember of the plurality of battery cell shock-attenuating members may beindividually attached to an outward facing surface of each battery cellof the plurality of battery cells; and (e) a housing that includes aninternal cavity, where the internal cavity receives the plurality ofbattery cells, the flexible PCB, the central shock-attenuating member,and the plurality of battery cell shock-attenuating members. A batterycell shock-attenuating member of the plurality of battery cellshock-attenuating members may contact an interior surface of thehousing. When a battery cell of the plurality of battery cells increasesin volume, one of a battery cell shock-attenuating member of theplurality of shock-attenuating members or the central shock-attenuatingmember may be compressed. In addition, when a battery cell of theplurality of battery cells increases in volume, the battery cell thatincreases in volume may expand into a cavity formed by an opening ineach battery cell shock-attenuating member of the plurality of batterycell. A thickness of a battery cell shock-attenuating member of theplurality of battery cell shock-attenuating members may be within arange of 4 percent and 12 percent of a thickness of a battery cell ofthe plurality of battery cells. The central shock-attenuating member maycontact both inward facing surfaces of the upper portion and the lowerportion of the flexible PCB.

Aspects of the disclosure provide solutions that address and overcometechnical problems associated with minimizing size of a portable batterysystem (e.g. a conformal wearable battery system).

A need has been recognized within the mobile electrical power storageindustry for increasing power capacity while improving an overall usersafety of these systems while simultaneously reducing their size andweight.

A matrix of battery cell modules includes a flexible printed circuitboard assembly (PCBA) for a conformal wearable battery (CWB) with aplurality of attachment sections for each of a plurality of batterycells that are arranged in a grid-like pattern on a same side of theflexible PCBA. Control and/or monitoring circuitry for the CWB may beprovided in a circuitry module. The flexible PCBA is configured to foldalong a bend axis so that the flexible PCBA is folded approximately inhalf. When affixed to the flexible PCBA, the plurality of battery cellmodules and the circuitry module form a grid of physical components.When folded, the flexible PCBA forms a three-dimensional grid ofphysical components comprising at least the battery cell modules.

Aspects of this disclosure may relate to a conformal wearable batterythat may include a plurality of battery cells and a flexible printedcircuit board assembly (PCBA). The flexible PCBA may include a pluralityof physical connection sections disposed in a grid like pattern, whereineach of the plurality of battery cells is physically affixed to theflexible PCBA at a corresponding physical connection section of theplurality of physical connection sections, a bend axis disposed betweentwo parallel physical connection sections, wherein the bend axisfacilitates folding of the flexible PCBA in half. Additionally, theflexible PCBA may include a plurality of first cut-outs disposed alongthe bend axis, wherein each first cut-out of the plurality of firstcut-outs is disposed parallel to the bend axis and a plurality of secondcut-outs disposed across the bend axis, wherein each second cut-out ofthe plurality of second cut-outs are disposed perpendicular to the bendaxis.

In some cases, the conformal wearable battery may include a firstplurality of electrical connections each connecting a cathode of acorresponding battery cell of the plurality of battery cells and secondplurality of electrical connections each connecting an anode of thecorresponding battery cell of the plurality of battery cells toelectrical conductors of the flexible printed circuit board assembly.Further, the conformal wearable battery may include a plurality ofbattery cells, at least one circuitry module configured to control andmonitor charging and discharging of the plurality of battery cells, anda flexible printed circuit board assembly (PCBA). The flexible PCBA mayinclude a plurality of physical connection sections disposed in a gridlike pattern, wherein each of the plurality of battery cells and the atleast one circuitry module is physically affixed to the flexible PCBA ata corresponding physical connection section of the plurality of physicalconnection sections.

Aspects of this disclosure may relate to a conformal wearable batterythat may include a flexible PCBA that includes a first plurality ofelectrical connections each connecting a cathode of a correspondingbattery cell of the plurality of battery cells and second plurality ofelectrical connections each connecting an anode of the correspondingbattery cell of the plurality of battery cells to electrical conductorsof the flexible printed circuit board assembly. The conformal wearablebattery may include a plurality of battery cells and at least onecircuitry module that, when affixed to the flexible PCBA, forms a matrixof physical components. The matrix of physical components may be amatrix of at least two rows and at least two columns. The conformalwearable battery may further include at least one connector configuredto provide an electrical power connection from internal circuitry of theconformal wearable battery to an external device to be powered. Aspectsof this disclosure may relate to a conformal wearable that may includethe plurality of battery cells, where the at least one connector, andthe at least one circuitry module, when affixed to the flexible PCBA,comprises a matrix of physical components.

Aspects of this disclosure may relate to a conformal wearable batterythat may comprise a bend axis that is a center of the grid like patternof the physical connection sections when the flexible PCBA is unfolded.The conformal wearable battery of the illustrative example may include aflexible PCBA having each of the plurality of battery cells physicallyattached to a first side of the flexible PCBA. The conformal wearablebattery may include the flexible PCBA having each of the plurality ofbattery cells physically attached to a first side of the flexible PCBAand each of the plurality of battery cells electrically connected to theflexible PCBA on a second side of the flexible PCBA that is opposite thefirst side. The conformal wearable battery of the illustrative examplemay include the flexible PCBA having the plurality of battery cellsdisposed on an outside surface of the flexible PCBA, when the flexiblePCBA is in a folded configuration.

Aspects of this disclosure may relate to a plurality of battery cellsthat are arranged in a three-dimensional grid pattern. The conformalwearable battery of the illustrative example may include a sealedflexible housing wherein the flexible PCBA is disposed within aninterior cavity of the sealed flexible housing and wherein the flexiblePCBA is in a folded configuration.

Aspects of this disclosure may relate to a system that may include aplurality of battery cell modules and a flexible printed circuit boardassembly (PCBA). The flexible PCBA may further include a plurality ofbattery cell connection sections disposed in a grid-like pattern along afirst surface of the flexible PCBA where each of the plurality ofbattery cell modules is electrically attached to the flexible PCBA on asecond surface of the flexible PCBA in a grid-like pattern, wherein thesecond surface is opposite the first surface. Aspects of this disclosuremay relate to the system that may further include a housing, wherein theflexible PCBA, when in a folded configuration, is located within thehousing. Aspects of this disclosure may relate to the illustrativesystem that may include a plurality of battery cell modules, where eachof the plurality of battery cell modules includes a battery cell and anattenuating member made of a resilient material. Each battery cell maybe a lithium-ion battery cell. The illustrative system may include aplurality of battery cells arranged in a three-dimensional grid patternwhen the flexible PCBA is in a folded configuration.

Aspects of this disclosure may relate to an illustrative flexibleprinted circuit board assembly (PCBA) may include a plurality of batterymodules physically affixed to the flexible PCBA, where the plurality ofbattery modules is arranged in a grid-like pattern and a bend axis nearan approximate mid-point of the flexible PCBA. When the flexible PCBA isbent along the bend axis, the flexible PCBA is in a folded configurationand, when the flexible PCBA is in a folded configuration, the pluralityof battery modules is disposed in a three-dimensional grid-like pattern.

Aspects of this disclosure may relate to a plurality of flexiblesections of the flexible PCBA, were the flexible sections may allow forthe flexible PCBA to flex between adjacent rows and adjacent columns ofbattery modules. The illustrative flexible PCBA may include at least onecircuitry module that comprises a portion of the grid-like pattern.

Additional aspects of this disclosure may relate to a conformal wearablebattery (CWB) including a plurality of battery cells, where each batterycell includes a pair of electrically conductive elements that correspondto either a cathode or an anode of each battery cell. The CWB may alsoinclude a flexible printed circuit board (PCB) that includes a pluralityof physical connection sections disposed in a grid like pattern on afirst side of the flexible PCB, where each of the plurality of batterycells is disposed at a corresponding physical connection section of theplurality of physical connection sections. The flexible PCB may furtherinclude a plurality of electrical connection pads linearly disposed on asecond side opposite the first side of the flexible PCB, the pluralityof electrical connection pads comprising an electrically conductivesurface coating. The pair of electrically conductive elements may extendsubstantially parallel to and along the second side of the flexible PCB,and each electrically conductive elements may be connected to acorresponding electrical connection pad of the plurality of electricalconnection pads on the second side of the flexible PCB forming anelectrical connection.

Aspects of the disclosure may relate to the plurality of battery cellscomprising pouch cell packaged polymer lithium-ion battery cells whereeach battery cell of the plurality of battery cells is physicallyattached to the first side of the flexible PCB.

Aspects of the disclosure may relate to a conformal wearable batterywhere the flexible PCB includes a plurality of cutouts extending throughthe flexible PCB, where at least one cutout of the plurality of cutoutsis located adjacent to an electrical connection pad of the plurality ofelectrical connection pads. In some cases, each conductive element ofthe pair of electrically conductive elements may extend through acorresponding cutout of the plurality of cutouts.

Aspects of the disclosure may relate to a conformal wearable batterywhere the electrically conductive surface coating comprises anelectroless nickel immersion gold (ENIG) surface coating and/or alead-free immersion silver surface coating.

Aspects of the disclosure may relate to forming an electrical connectionbetween each electrically conductive element of the pair of electricallyconductive elements and the corresponding electrical connection pad ofthe plurality of electrical connection pads with a weld. In some cases,the weld is formed using a laser welding process. In some cases, theweld is formed using an ultrasonic welding process.

Aspects of the disclosure may relate to a conformal wearable batterywhere a connection pad of the plurality of electrical connection padshas a width that is within a range of 1.8 times and 3 times a width ofan electrically conductive element of the pair of electricallyconductive elements and/or where a height of an electrical connection iswithin a range of 1.2 to 3 times a thickness of an electricallyconductive element of the pair of electrically conductive elements. Insome cases, a connection pad of the plurality of electrical connectionpads may have a circular shape with a diameter that is within a range of1.8 times and 3 times a width of an electrically conductive element ofthe pair of electrically conductive elements.

Aspects of the disclosure may relate to a system including a firstplurality of battery cells and a second plurality of battery cells and aflexible printed circuit board (PCB). In some cases, the first batterycell of the first plurality of battery cell includes a first pair ofelectrically conductive elements and the second battery cell of thesecond plurality of battery cell includes a second pair of electricallyconductive elements. The flexible PCB may include a plurality of batterycell connection sections disposed in a grid-like pattern along a firstsurface of the flexible PCB, a plurality of cutouts disposed adjacentand parallel to an edge of the plurality of battery cell connectionsections, and a plurality of electrical connection pads disposed on asecond surface of the flexible PCB opposite the first surface. In somecases, the plurality of cutouts may be arranged as multiple pairs ofcutouts arranged adjacent a majority of the plurality of battery cellconnection sections and/or a majority of the plurality of electricalconnection pads may be arranged adjacent the plurality of cutouts, andwhere the plurality of electrical connection pads may include anelectrically conductive surface coating. In some cases, an electricallyconductive element of the first pair of electrically conductive elementsmay wrap around an edge of the flexible PCB and may extend along thesecond surface of the flexible PCB such that the electrically conductiveelement of the first pair of electrically conductive elements may beconnected to a corresponding electrical connection pad of the pluralityof electrical connection pads forming a first electrical connection. Insome cases, an electrically conductive element of the second pair ofelectrically conductive elements may extend through a cutout of theplurality of cutouts such that each electrically conductive element ofthe second pair of electrically conductive elements may be connected toa corresponding electrical connection pad of the plurality electricalconnection pads forming a second electrical connection.

Aspects of this disclosure may relate to a flexible printed circuitboard assembly (PCBA) that may include a flexible printed circuit board(PCB) and a plurality of battery cell modules physically affixed to thefirst side of the flexible PCB. The flexible PCBA may have a first sideand a second side opposite the first side, where a plurality ofelectrical connection pads may be disposed on the second side of theflexible PCB. The plurality of electrical connection pads may bearranged in multiple pairs of electrical connection pads. In some cases,the plurality of electrical connection pads may include an electricallyconductive surface coating. The flexible PCBA may include a plurality ofcutouts linearly disposed in the flexible PCB and adjacent tocorresponding electrical connection pads. In some cases, the pluralityof battery cell modules may be arranged in a grid-like pattern andcomprise pouch cell packaged polymer lithium-ion and each battery cellmodule of the plurality of battery cell modules may include a pair ofelectrically conductive elements that extend substantially parallel tothe second side of the flexible PCB and may be configured to connect tocorresponding electrical connection pads of the plurality of electricalconnection pads to form an electrical connection for each battery cellmodule.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated by way of example and not limitedin the accompanying figures in which like reference numerals indicatesimilar elements and in which:

FIG. 1 illustrates an exploded perspective view of an exemplaryconformal wearable battery (CWB) according to aspects described herein;

FIG. 2 illustrates a cross-sectional view of an electrical contactregion of an exemplary CWB housing according to aspects describedherein;

FIG. 3 illustrates a partial perspective view of the electrical contactregion of an exemplary CWB housing according to aspects describedherein;

FIGS. 4A and 4B illustrate perspective views of an exemplary contactcomponent from different vantage points according to aspects describedherein;

FIGS. 5A and 5B illustrate side and front views of an exemplary contactcomponent according to aspects described herein;

FIG. 6 illustrates a flowchart of exemplary assembly steps performed toencase the contact component into a portion of the CWB housing beforethe CWB housing is sealed closed in a molding process according toaspects described herein;

FIG. 7 illustrates a front perspective view of another exemplary housingof the CWB of FIG. 1 according to aspects described herein;

FIG. 8 illustrates an exploded front perspective view of the exemplaryhousing of FIG. 7 according to aspects described herein;

FIG. 9 illustrates an exploded rear perspective view of the exemplaryhousing of FIG. 7 according to aspects described herein;

FIG. 10 illustrates a cross-sectional perspective view of the exemplaryhousing of FIG. 7 along line 10-10 according to aspects describedherein;

FIG. 11 illustrates an enlarged view of FIG. 10 according to aspectsdescribed herein;

FIG. 12 illustrates a partial cross-sectional view of the exemplaryhousing of FIG. 7 along line 12-12 according to aspects describedherein;

FIG. 13 illustrates a partial perspective view of a first member of oneof the shells of the exemplary housing of FIG. 7 according to aspectsdescribed herein;

FIG. 14 illustrates a cross-sectional view of an alternate example of ajoint between a first member and a second member of one of the shells ofthe exemplary housing of FIG. 7 according to aspects described herein;

FIG. 15 illustrates an exploded perspective view of another exemplaryhousing of the CWB of FIG. 1 according to aspects described herein;

FIG. 16 illustrates a front top perspective view of another exemplaryconformal wearable battery (CWB) according to aspects described herein;

FIG. 17 illustrates a rear bottom perspective view of the conformalwearable battery of

FIG. 16 according to aspects described herein;

FIG. 18A illustrates an exploded perspective view of the exemplaryconformal wearable battery of FIG. 16 according to aspects describedherein;

FIG. 18B illustrates a partial perspective view of the exemplary CWB ofFIG. 16 with some components removed for clarity according to aspectsdescribed herein;

FIG. 19 illustrates a perspective view of a lower shell of a housing forthe exemplary conformal wearable battery of FIG. 16 according to aspectsdescribed herein;

FIG. 20 illustrates an exploded perspective view of the lower shell ofFIG. 19 according to aspects described herein;

FIG. 21 illustrates an enlarged perspective view of a portion of thelower shell of FIG. 19 according to aspects described herein;

FIG. 22 illustrates a cross-sectional perspective view of a portion ofthe lower shell of the housing along line 22-22 of FIG. 19 according toaspects described herein;

FIG. 23 illustrates a cross-sectional perspective view of a portion ofthe lower shell of the housing along line 23-23 of FIG. 21 according toaspects described herein;

FIG. 24 illustrates a perspective view of a contact carrier assembly ofthe conformal wearable battery (CWB) of FIG. 16 according to aspectsdescribed herein;

FIG. 25 illustrates an exploded perspective view of the contact carrierassembly of FIG. 24 according to aspects described herein;

FIGS. 26A and 26B illustrate front and rear perspective views of acontact component of the contact carrier assembly of FIG. 24 accordingto aspects described herein;

FIGS. 27A-27D illustrate front, rear, and side views of a contactcomponent of the contact carrier assembly of FIG. 24 according toaspects described herein;

FIG. 28 illustrates a flowchart of exemplary steps to form the housingand assemble the battery cells into the housing to form the CWB;

FIG. 29 shows a first view of an illustrative flexible printed circuitboard for an illustrative conformal wearable battery system according toaspects of the present disclosure;

FIG. 30 shows a second view of the illustrative flexible printed circuitboard for the illustrative conformal wearable battery system accordingto aspects of the present disclosure;

FIG. 31 shows a partial second view of the illustrative flexible printedcircuit board including cut-outs providing strain relief along a centerline according to aspects of the present disclosure;

FIG. 32 shows a first view of the illustrative flexible printed circuitboard folded along the center line according to aspects of the presentdisclosure;

FIGS. 33 and 34 show a partial side view of the flexible printed circuitboard when folded along the center line according to aspects of thepresent disclosure;

FIGS. 35 and 36 show partial views of the flexible printed circuit boardwhen folded along the center line according to aspects of the presentdisclosure;

FIGS. 37A and 37B show first views of a flexible printed circuit boardassembly before folding along the center line according to aspects ofthe present disclosure;

FIGS. 38A and 38B show second views of the flexible printed circuitboard assembly before folding along the center line according to aspectsof the present disclosure;

FIG. 39 shows a partial first view of the flexible printed circuit boardassembly according to aspects of the present disclosure;

FIG. 40 shows a side view of the flexible printed circuit board assemblybefore folding along the center line according to aspects of thedisclosure;

FIG. 41 shows a side view of the flexible printed circuit board assemblyafter folding along the center line according to aspects of thedisclosure;

FIGS. 42A and 42B show first views of the flexible printed circuit boardassembly after folding along the center line according to aspects of thedisclosure;

FIG. 43 shows a partial side view of the flexible printed circuit boardassembly after folding along the center line according to aspects of thedisclosure;

FIG. 44 shows a partial first view of the flexible printed circuit boardassembly after folding along the center line according to aspects of thedisclosure;

FIG. 45 shows a view of another flexible printed circuit board for anillustrative conformal wearable battery system according to aspects ofthe present disclosure;

FIG. 46A shows a folded configuration of the flexible printed circuitboard of FIG. 45 according to aspects of the disclosure;

FIGS. 46B and 46C show a view of illustrative flexible connectorportions of the flexible printed circuit board of FIG. 45 according toaspects of the disclosure;

FIG. 46D shows a view of the illustrative flexible printed circuit boardof FIG. 42B according to aspects of the disclosure;

FIGS. 47A-47D show illustrative views of a second design of anillustrative flexible printed circuit board assembly according toaspects of the disclosure;

FIG. 48 illustrates a front perspective view of a battery cell assemblyfor a conformal wearable battery (CWB) according to aspects describedherein;

FIG. 49 illustrates a rear perspective view of the battery cell assemblyof FIG. 1 according to aspects described herein;

FIG. 50A illustrates a front exploded perspective view of a conformalwearable battery with the battery cell assembly of FIG. 48 according toaspects described herein;

FIG. 50B illustrates a front perspective view of the conformal wearablebattery of FIG. 50A according to aspects described herein;

FIG. 51 illustrates a cross-sectional side view of the CWB of FIG. 50Baccording to aspects described herein;

FIG. 52 illustrates a rear view of the battery cell assembly of FIG. 48with some components removed for clarity according to aspects describedherein;

FIG. 53 illustrates a front perspective view of an exemplary centralshock-attenuating member of the battery cell assembly of FIG. 48according to aspects described herein;

FIG. 54 illustrates a front view of a portion of the battery cellassembly of FIG. 48 according to aspects described herein;

FIG. 55 illustrates a front perspective view of an exemplary batterycell shock-attenuating member of the battery cell assembly of FIG. 48according to aspects described herein;

FIG. 56 shows a first view of an illustrative flexible printed circuitboard for an illustrative conformal wearable battery system according toaspects of the present disclosure;

FIG. 57 shows a second view of the illustrative flexible printed circuitboard for the illustrative conformal wearable battery system accordingto aspects of the present disclosure;

FIG. 58 shows a partial second view of the illustrative flexible printedcircuit board including markings for placement of two battery modules;

FIG. 59 shows a first view of the illustrative flexible printed circuitboard folded along the bend line according to aspects of the presentdisclosure;

FIGS. 60A-60C show first views of flexible printed circuit boardassemblies (PCBA) before folding along the bend line according toaspects of the present disclosure;

FIG. 61 shows a second view of the flexible PCBA before folding alongthe bend line according to aspects of the present disclosure;

FIG. 62 shows a partial first view of the flexible printed circuit boardassembly showing a partial arrangement of adjacent battery cell moduleswhen attached in an array or matrix format on the flexible PCBAaccording to aspects of the present disclosure;

FIG. 63 shows a side view of the flexible PCBA before folding along thebend line according to aspects of the disclosure;

FIG. 64 shows a side view of the flexible PCBA after folding along thecenter line according to aspects of the disclosure;

FIG. 65 shows a first view of the flexible printed circuit boardassembly after folding along the bend line according to aspects of thedisclosure;

FIG. 66 shows a partial side view of the flexible PCBA after foldingalong the bend line;

FIG. 67 shows a partial first view of the flexible PCBA after foldingalong the bend line according to aspects of the disclosure;

FIGS. 68A-68D show different views of an illustrative battery cell 1300according to aspects of the disclosure;

FIGS. 69A-69E show illustrative views of a battery cell modulecomprising a battery cell and a battery cell attenuating memberaccording to aspects of the disclosure;

FIGS. 70A-70E show partial illustrative views of at least one batterycell module being attached to the flexible PCBA according to aspects ofthe disclosure;

FIGS. 71 and 72 show different perspective views of a battery cellmatrix or grid associated with a flexible PCBA according to aspects ofthe present disclosure ;

FIGS. 73A-73D show different side views of the flexible PCBA from aperspective of each of four different edges according to aspects of thisdisclosure;

FIGS. 74 and 75 show partial views of the illustrative PCBA of oppositesides near the connector module, according to aspects of thisdisclosure;

FIGS. 76 and 77 illustrate an illustrative conformal wearable battery(CWB) including a matrix of internal battery cell modules according toaspects of this disclosure;

FIG. 78 shows an illustrative installation process for attaching eachbattery cell module to the flexible PCB according to aspects of thisdisclosure;

FIG. 79 illustrates a front view of a portion of the battery cellassembly according to aspects described herein;

FIG. 80 shows a front view of a portion of the electrical connections ofthe battery cell assembly according to aspects described herein;

FIGS. 81A and 81B illustrate configurations of redundant trace fusesaccording to aspects described herein; and

FIG. 82 shows an illustrative method of use of a redundant trace fusestructure according to aspects described herein.

DETAILED DESCRIPTION

In the following description of various illustrative arrangements,reference is made to the accompanying drawings, which form a parthereof, and in which is shown, by way of illustration, variousarrangements in which aspects of the disclosure may be practiced. It isto be understood that other arrangements may be utilized, and structuraland functional modifications may be made, without departing from thescope of the present disclosure. The drawings may not be shown to scale.

It is noted that various connections between elements are discussed inthe following description. It is noted that these connections aregeneral and, unless specified otherwise, may be direct or indirect, andthat the specification is not intended to be limiting in this respect.

For a product and/or case in which a sealed fit is a useful feature,typical sealing techniques that use glue, adhesives, welding, orsoldering may not always form a robust seal especially around complexshapes. When a seal's integrity is compromised, contaminants may breachthe seal and cause damage within the product. The seal's integrity maybe compromised by cracks, voids, stress fractures, and/or other defectsassociated with or caused by the sealing techniques within a materialassociated with the seal. For example, a glue or an adhesive may loseadhesion to the material associated with the seal, stress fractures inthe material may be caused by heat associated with welding or soldering,or a void leading to a breach of the seal may form when performingsoldering or welding. Heat from welding or soldering techniques maycause the material of the case to liquify and flow at the location ofthe desired seal, thereby preventing a reliable seal from being formed.As a result, attempts to seal an electrical conductor, for example,passing through a material enclosing a product using typical sealingtechniques may result in failure of the seal, breaching of the seal byfluid and/or contaminants, and/or damage to the product protected by theseal.

Disclosed herein is a method of installing an electrically conductivecomponent passing through an exterior wall of a sealed case or housingby an insert molding process. An insert molding process may providegreater reliability and integrity of the seal, as well as an improvedcosmetic appearance of the seal compared to typical sealing techniques.The electrically conductive component may include a plurality of knurledregions for making a friction fit with a wall of the molded case tocreate a seal between the electrically conductive component and thematerial of the molded case, which may be a polymeric material. Thefriction fit produced by the insert molding process may avoid theabove-mentioned failure modes associated with sealing a space between anelectrically conductive component and an edge of a material of a casewith glue, adhesive, welding, or soldering. For example, the insertmolding process may avoid application of high levels of heat at thejoint between the electrically conductive component and the material ofthe case as may be applied in a soldering or welding process.

The seal produced between the electrically conductive component and thematerial of the molded case may satisfy requirements of an InternationalElectrotechnical Commission (IEC) IP67 rating for preventing dust andwater ingress to the case and creating a water-tight fit between theelectrically conductive component and the case in which the electricallyconductive component is disposed. The IP67 rating is specified by theIngress Protection Code (IP Code) IEC standard 60529. The equivalentEuropean standard is EN 60529. The IP Code also may be referred to asthe International Protection Code. The IP Code classifies and rates adegree of ingress protection provided by mechanical casings andelectrical enclosures for electronic equipment against intrusion, dust,accidental contact, and liquid (e.g., water). In the IP67 rating, thefirst digit (i.e. ‘6’) specifies a level of protection offered againstingress of solid objects, while the second digit (i.e. ‘7’) specifies alevel of protection offered against ingress of liquids. The larger thevalue of the digit specifying the level of protection, the greater theamount of protection offered. For example, an IP67 rating specifiestotal protection against dust ingress and protection against shortperiods of immersion in water. An IP68 rating specifies dust resistanceand immersion in 1.5 meters of freshwater for up to 30 minutes duration.

A reliable seal, for example, an IP67 rated seal, may be desirable andbeneficial for protection and maintenance of batteries enclosed inenvironmentally protected housings. Such a battery for poweringelectronic devices in outdoor environments, for example, in dusty,sandy, rainy, and/or wet environments, may fail early if contaminantssuch as water, dust, dirt, and/or sand get into the battery enclosed inthe housing. A rechargeable conformal wearable battery (CWB) assemblymay be worn by a user to power electronic devices that the user carries.The CWB assembly may be subjected to environmental conditions that maycause the CWB (and its housing) to physically deform or bend while alsobeing exposed to moisture. A reliable seal may facilitate longer batterylife and utility for the user regardless of environmental conditionsthat the CWB may be subjected.

A CWB assembly may include an array of a first quantity of battery cellsdisposed adjacent to one another in a horizontal direction and a secondquantity of battery cells disposed adjacent to one another in a verticaldirection. The array of battery cells may be arranged in a grid-likepattern. Each of the battery cells may be separate from other batterycells. A battery cell as described herein may include a plurality ofindividual battery cell elements that are electrically connectedtogether to form a compound battery cell that electrically performs as asingle unit. Each of the battery cells may be physically connected toadjacent battery cells by flexible elements (e.g., a flexible printedcircuit board), thereby facilitating a surface outline or shape of thearray of battery cells to generally conform to a surface outline orshape of a user wearing the CWB assembly. One or more of the batterycells may include a positive-charge electrical terminal and anegative-charge electrical terminal that are electrically connected withthe battery cell within an interior of the battery cell and provideelectrical power to electrical devices disposed exterior to the batterycell. Electrical terminals of a plurality of the battery cells in thearray of battery cells may be connected together to route electricalcurrent through the plurality of the battery cells and a set ofpositive-charge and negative-charge electrical terminals that are sharedamong the plurality of the battery cells. The positive-charge electricalterminal and the negative-charge electrical terminal may provide anelectrical current that passes through an electrically conductive path,for example, through an electronic device, via transfer of electronsthrough the electrically conductive path between the positive-chargeelectrical terminal and the negative-charge electrical terminal on theexterior of the housing. The CWB assembly may include a set ofpositive-charge and negative-charge electrical terminals that are sharedamong the plurality of the battery cells of the array of battery cells.The plurality of the battery cells may be electrically coupled together,for example, in series, in parallel, or in groups of series connectedbattery cells connected in parallel, etc.

The CWB housing may be formed from molded components. The molded housingcomponents may form a sealed case. Each of the housing components may beformed by a molding process, for example, an injection molding process.The molded casing may be formed of a polymeric material, for example.The casing may be sealed to prevent ingress of solid material and/orliquid material, for example, according to an IP67 rating, IP68 rating,or other ingress protection rating. The casing may feature a seambetween two components or portions of the casing that is sealed toencase the battery cell within the casing. The positive-charge terminaland the negative-charge terminal may each include a conductive contactcomponent that passes between the interior of the CWB housing and theexterior of the CWB housing. The conductive region may include aflexible circuit, wiring or PCBA that is affixed and electricallyconnected to the battery cells in an interior of the housing at one end,and electrically connected to a contact component that passes through awall of the casing, and electrically couples with electrical devices atan exterior of the CWB housing. The details of the housing are describedin more detail below.

The contact component may include a textured region on an exterior ofthe contact component that is adjacent to and/or interfaces with thewall of the housing. In some examples, the textured region may includetwo separate knurled areas and a recessed groove between the two knurledareas. The contact component may include a threaded element that mateswith a corresponding threaded conductive element that electricallyconnects to conductive region (i.e. flexible circuit, wiring) of thebattery cells. The threaded element of the contact component may includea female threaded element. The female threaded element of the contactcomponent may mate with a corresponding male threaded conductiveelement. A thread pitch or thread count of the threaded element of thecontact component may match a thread pitch or thread count of thecorresponding threaded element of the conductive element. The contactcomponent may be physically and electrically accessible outside of thehousing, for example, at an exterior of the cell housing. For example,the contact component may have an outward facing surface that isaccessible outside housing. The contact component may be in directphysical and electrical contact with the conductive region inside thehousing. The textured region of the exterior of the contact componentmay form a seal at an interface with the casing, for example, at a wallof the casing that prevents ingress of solids and/or liquids into theinterior region of the casing according to an IP rating.

FIG. 1 illustrates an exploded perspective view of an exemplaryconformal wearable battery (CWB) 10 according to aspects describedherein. FIG. 2 illustrates a cross-section view of an electrical contactregion of an exemplary CWB housing 100. The battery cells 20 may beinstalled into the housing 100. An electrically conductive fastener 105(e.g., a screw or a bolt) may provide an electrically conductive pathfrom an interior 110 of the CWB housing 100 to an exterior 115 of theCWB housing 100. A battery cell terminal 120 may be electricallyconnected with one end (e.g., a head) of the electrically conductivefastener 105 in the interior 110 of the CWB housing 100. Theelectrically conductive fastener 105 may have a shaft portion 150 thatpasses through an opening in a printed circuit board assembly (PCBA) 125and mates with a corresponding hole 155 in a contact component 130 inelectrical and physical communication with an exterior 115 of the CWBhousing 100. Alternatively, the PCBA may be a flexible circuit boardassembly or maybe, at least partially replaced by a wiring harness. Theshaft portion 150 of the electrically conductive fastener 105 mayinclude a threaded region (e.g., a male threaded region) that mates witha corresponding threaded region (e.g., a female threaded region) of thecontact component 130. The contact component 130 may include two or moreknurled regions 135 that are separated by one or more groove regions140. Diameters and/or widths of the two or more knurled regions 135 maybe equal or different. Diameters and/or widths of the one or more grooveregions 140 may be equal or different. Dimensions associated withdifferent aspects and regions of the contact component 130 may vary. Adifference in diameter between a groove region 140 and a knurled region135 may be within a range of one to three (1.0 to 3.0) times a width ofa knurled region 135, for example. A width of the groove region 140 maybe within a range of one-half to four (0.5 to 4.0) times a width of aknurled region 135, for example. A wire 145 may electrically connectwith an interior side of the PCBA 125 on one or more of the sides of theelectrically conductive fastener 105.

While the preceding example of FIG. 1 refers to a female threadedelement of the contact component 130 for receiving a male conductiveelement 105, the disclosure is not so limited. Rather, the male andfemale elements may be reversed in that the contact component 130 mayconsist of the male element and the conductive region may be securedusing a female threaded element. Moreover, while some embodiments maydescribe a threaded means for mating the male and female element, inother embodiments the means for mating may comprise other methodsavailable to those of ordinary skill such as friction fitting, anexpandable/collapsible that latches the two elements together, or othermating techniques.

FIG. 3 illustrates a perspective view of the electrical contact regionof one lower housing 205 of the exemplary CWB housing 100. The lowerhousing 205 may be illustrated as a cut-away for ease of viewing thecontact components 130 embedded within the wall of the lower housing205. The lower housing 205 may comprise the contact components 130seated and encased in the exterior wall after an injection moldingprocess. The material of the molded walls may be formed by the injectionmolding process to closely and tightly fit the shape of the knurledregions 135 and the groove regions 140 of the contact components 130.The lower housing 205 may be formed by an injection molding process inwhich the contact components 130 are positioned and fixed in place in amold prior to forming the lower housing 205 in the mold. When thematerial for the lower housing 205 is injected into the mold, thematerial flows around the knurled regions 135 and the groove regions 140of the contact components 130 forming a mechanical lock around thecontact components 130 after the material solidifies.

An upper housing (not shown) that mates with the lower housing 205 maybe seated over the lower housing 205 of the CWB housing 200 and fittogether during assembly. A seam between the upper housing and the lowerhousing 205 may be formed to seal (e.g., by laser welding) the upperhousing and lower housing 205 of the CWB housing 200 to each other,while the knurled regions 135 and the groove regions 140 of the contactcomponents 130 may be fully encased and sealed within the lower housing205 of the CWB housing 200.

One or more of the electrically conductive fasteners 105 may passthrough a hole in a corresponding PCBA 125, with a head end of theelectrically conductive fasteners 105 disposed on a side of the PCBA 125facing an interior 210 of the CWB housing 100, and an opposite (e.g.,threaded or shaft end) of the electrically conductive fasteners 105inserted through the PCBA 125 and into and/or mated with correspondingcontact components 130 on an opposite side of the PCBA 125 that facesthe exterior 215 of the CWB housing 100. The electrically conductivefasteners 105 may secure the PCBA 125 against the inward facing surfaceof the contact components 130. The electrically conductive fasteners 105may electrically connect an electrically conductive plate and/orelectrical trace of the PCBA 125 with a corresponding interior-facingside of the contact component 130. One end of the wires 145 may beelectrically connected to electrically conductive traces and/orelectronic circuitry disposed on the PCBA 125. The one or more of thewires 145 may be directly and/or electrically connected to the fasteners105. In some examples (not shown), the PCBA 125 may be replaced by awasher to which a corresponding end of a wire 145 is connected. Anopposite end of the wires 145 may be connected to one of a positivebattery cell terminal, negative battery cell terminal, protectioncircuitry, data circuitry, clock circuitry, or other circuitryassociated with the battery cells 20. Circuitry associated with thebattery cells 20 may include battery charging control circuitry, forexample. The wires 145 may carry electrical current and/or data signalsbetween the battery cell and/or associated circuitry within the interior210 of the CWB housing 100 and the contact component accessible on theoutside 215 of the CWB housing 100. Dimensions of the various componentsshown in FIGS. 1-3 may vary and may have different relative scales thanshown in the drawings without departing from the disclosure herein.

FIGS. 4A, 4B, 5A, and 5B illustrate views of an exemplary contactcomponent 130 from different vantage points. A plurality of knurledregions 135, for example, two as shown in FIGS. 4A, 4B, and 5A, may beseparated by one or more groove regions 140. The knurled regions 135 ofthe contact component 130 may have a greater diameter than the one ormore groove regions 140. A width of the knurled regions 135 may begreater than, the same as, or less than a width of the one or moregroove regions 140. The knurled regions 135 may include crossed linesthat form a surface texture of the knurled regions 135. The crossedlines may be formed by machining, drilling, laser cutting, or millingoperations performed on the contact component 130. The crossed lines maycreate triangular and/or diamond-shaped regions in the knurled regions135. The crossed lines of the knurled regions 135 and the one or moregroove regions 140 may assist with the adhesion of the material withwhich the molded CWB housing is formed to the contact component 130.When the contact component 130 is inserted into the mold for the CWBhousing 100 and the material for the lower housing 205 is flowed throughthe interface between the curved exterior surface of the contactcomponent 130 (e.g., comprising the knurled regions 135 and the one ormore groove regions 140) and a edge of the CWB housing 100, the materialmay enter and solidify within at least a portion of the cross-hatchedgrooves of the knurled regions 135 and the groove region 140 to form asolid attachment to and high quality seal (e.g., IP67, IP68, or better)with the curved exterior surface of the contact component 130. Theoutward facing surface 136 may interface with an external electricaldevice that uses the CWB 10.

At least one advantage of the aforementioned method is that ahigh-quality friction fit is produced without exposing the materials toglue, adhesive, welding, and/or soldering. For example, by avoidingsoldering and welding, the aforementioned process avoids application ofhigh levels of heat at the joint between the electrically conductivecomponent and the edge of the material of the case as may be applied ina soldering or welding process. Unlike systems that may rely upon anapplication of heat, the aforementioned embodiment is an improvementbecause, inter alia, it creates a high-quality seal without relying uponan application of heat or a messy, potentially manual application ofglue to join two or more pieces of a casing/housing.

The contact component 130 may have features and characteristics thatvary from those illustrated in FIGS. 4A, 4B, 5A, and 5B withoutdeparting from the disclosure herein. The material of the contactcomponent 130 may comprise brass, gold, copper, silver, aluminum, steel,or other electrically conductive material or combination of one or moreelectrically conductive materials. Relative dimensions of one or moreportions of the contact component 130 may vary from those shown. Thehole 155 may be optionally included or omitted. The hole 155 maycomprise a fitting portion configured to mate with the electricallyconductive fastener 105. For example, the hole 155 may comprise threadedwalls that mate with a threaded shaft of the electrically conductivefastener 105. The hole 155 and the shaft of the electrically conductivefastener 105 may both have a same or compatible thread count or threadpitch. The hole 155 may be replaced by a protrusion, shaft, bolt, or thelike, and the mating electrically conductive fastener 105 may bereplaced by a socket, nut, crimp, or other fastener that mates with aprotrusion, shaft, bolt, or the like, for example, by havingcorresponding thread pitch or thread count. The hole 155 or replacementmay facilitate robust, secure, and reliable attachment of the contactcomponent to interior components, for example, electrical conductors,electrical or electronic circuits, mechanical components such as screwsthat hold components such as PCBAs in position, etc.

FIG. 6 illustrates a flowchart of exemplary assembly steps performed toencase the contact component 130 into the CWB housing 100 using aninjection molding process.

In operation 505, contact components (e.g., compact components 130) maybe positioned in a mold for forming the lower housing of the CWB housing(e.g., lower housing 205). The contact components 130 may be seated in aportion of the mold that forms an outer wall of the lower housing 205.The mold may be arranged to keep the contact components 130 from movingduring the molding process.

In operation 510, an injection molding process may be performed to formthe lower housing 205 of the CWB housing with the contact componentsembedded within the edge or side of the lower housing of the CWBhousing. A polymeric material may be injected into the mold and flowthrough the mold to form the lower housing 205. The material may flowaround the edges of the contact components 130 that are positioned inthe mold. For example, the material may flow around and/or through thecrossed lines or cross-hatching of the knurled regions and into thegroove regions between the knurled regions of the contact components 130to form a seal between the lower housing 205 of the molded CWB housingand the contact components 130. As the material solidifies, the materialmay form a strong, robust, and reliable seal with the contact components130. The lower housing 205 may be molded to encase the curved walls ofthe contact components 130 that comprise the knurled regions 135 and theone or more groove regions 140 while exposing opposite ends of thecontact components 130 to the interior and the exterior of the lowerhousing 205.

The knurled regions 135 and one or more groove regions 140 may improvethe seal between the contact components 130 and the lower housing 205 byforming a mechanical lock to secure the contact components 130 withinthe lower housing 205. The mechanical lock may be formed by thevariations in radius of the contact components 130 through the knurledregions 135 and the one or more groove regions 140. The knurled regions135 and one or more groove regions 140 may improve a seal between thecontact components 130 and the lower housing 205 compared to traditionalcontact components that do not include the features of the knurledregions and one or more groove regions. A path length along a surface ofthe contact component 130 including the knurled regions 135 and one ormore groove regions 140 from an end facing the interior of the lowerhousing 205 to an end facing the exterior of the lower housing 205 maybe longer than a corresponding path length in the traditional contactcomponent that does not include the features of the knurled regions andone or more groove regions. The variations in radius of the contactcomponents 130 through the knurled regions 135 and the one or moregroove regions 140 may increase the path length along the surface of thecontact component 130 including the knurled regions 135 and one or moregroove regions 140 compared to traditional contact components that donot include the features of the knurled regions and one or more grooveregions. The increased path length may also increase a surface area ofthe contact component 130 that contacts and forms a seal with the wallof the lower housing 205 in which the contact component 130 is embedded,and this surface area may be greater than a corresponding surface areaof the traditional contact component, that does not include the featuresof the knurled regions and one or more groove regions, adjacent to awall of a housing. The increase surface area may improve adhesionbetween the mold material that directly contacts the contact components130 compared to an alternative similarly sized traditional contactcomponent lacking the knurled regions and one or more groove regions.Flowing the material around and through the knurled regions 135 and theone or more groove regions 140 during the injection molding process ofthe lower housing 205 may form a stronger, more reliable, and tighterbond between the material of the housing 205 and the contact components130 than using glue, adhesive, or reflowing a liquid material betweenalternative similarly-sized contact components and a previously moldedhousing.

In operation 515, the molded lower housing 205 of the CWB housing havingthe embedded contact components 130 may be inspected. The inspection mayinclude visual inspection, machine vision, and/or image processing toidentify any voids, cracks, or regions of the molded lower housing 205that do not meet minimum thickness requirements. The inspection may beperformed using light in a visual spectrum region, infrared spectrumregion, or other spectrum region.

In operation 520, a determination may be made regarding whether themolded lower housing of the CWB housing passes specified qualitystandards. If the inspection does not pass the specified qualitystandards, the failed molded lower housing 205 of the CWB housing withembedded contact components may be discarded in operation 525. The partsof the failed molded lower housing 205 of the CWB housing with embeddedcontact components 130 may be recycled. Following the discard and/orrecycling of operation 525, the method may return to operation 505 tobegin again with another set of materials. If the inspection does passthe specified quality standards in operation 520, the method may proceedto operation 530.

In operation 530, interior components 20 of the CWB 10, for example, oneor more battery cell elements, PCBAs, wires, electronic circuits, andelectrically conductive fasteners 105 that mate with the contactcomponents 130, may be assembled and installed in the dried andsolidified lower housing 205 of the molded CWB housing. The interiorcomponents 20 of the CWB 10 may be seated against and/or attached to theinterior wall(s) of the molded CWB housing. The interior components 20of the CWB 10 may be electrically coupled with the contact components130 via the electrically conductive fasteners 105 being mated withcorresponding holes of the contact components 130 accessible from theinterior of the lower housing 205. The interior components 20 of the CWBmay be tested for functionality before or when being installed, and anyproblems discovered by testing the interior components 20 may beidentified and corrected before advancing to the next assemblyoperation.

In operation 535, a mold for an upper housing of the CWB housing, forexample, a mold for forming an upper housing that mates with lowerhousing 205, may be used to form the upper housing by an injectionmolding process. A polymeric material may be injected into the mold forthe upper housing of the CWB housing and flow through the mold whilebeing molded into a shape of the upper housing of the CWB housing.

In operation 540, the molded upper housing may be disposed adjacent tothe molded lower housing 205 of the CWB housing having the contactcomponents encased therein. The upper housing and the lower housing maybe attached, glued, welded, or laser welded together to secure and forma seal between the upper housing and the lower housing to seal theinterior of the CWB housing. The attachment process may form a strong,robust, and reliable seal between the upper housing and the lowerhousing of the CWB housing.

In operation 545, the molded lower housing 205 having the embeddedcontact components 130 may be inspected. The inspection may include boththe upper housing and the previously inspected lower housing 205 of themolded CWB housing, including seams between the upper and lowerhousings. The inspection may include visual inspection, machine vision,and/or image processing to identify any voids, cracks, or regions of themolded CWB housing that do not meet minimum thickness requirements. Theinspection may be performed using light in a visual spectrum region,infrared spectrum region, or other spectrum region. The inspection mayinclude immersion tests according to a standard, for example, the IPCode, to detect whether any solids and/or liquids are able to enter theinterior of the CWB housing within test conditions.

In operation 550, a determination may be made regarding whether themolded CWB housing passes specified quality standards. If the inspectiondoes not pass the specified quality standards, the failed molded CWBhousing with embedded contact components may be discarded in operation555. The parts of the failed molded CWB housing with embedded contactcomponents may be recycled. Following the discard and/or recycling ofoperation 555, the method may return to operation 505 to begin againwith another set of materials. If the inspection does pass the specifiedquality standards in operation 550, the method may end with a completedmolded CWB housing.

While aspects of the disclosure have been described with reference tobattery cells and/or a CWB comprising battery cells, arrangements andmethods as described herein may also be applied to other devices andsystems having one or more objects or inserts that communicate betweenan interior region and an exterior region of a housing. For example, thearrangements and methods described herein may apply to any electronicdevice disposed within a housing for which protection against immersionin liquids and/or intrusion of solids or fluids is desired. Exampleelectronic devices may include underwater cameras, sonar devices, radardevices, lidar devices, emergency radio beacons, satellitecommunications devices, terrestrial wireless communications devices,global positioning system (GPS) receivers, electronic environmentalsensor devices, electronic medical devices, solar cell based powergeneration devices, wave motion based power generation devices, fuelcell based power generation devices, and/or portable chemical batteriesfor powering electronic or electrical devices.

Turning now to another exemplary housing 300 for the exemplary conformalwearable battery (CWB) 10 shown in FIG. 1. Housing 300 may have similarproperties as housing 100, 200 described above with respect to thecontact components 130 being insert molded to one of the shells ofhousing 300 to seal around the contact component 130. The CWB 10 maybend or move in both a horizontal and/or vertical direction, or move insome combination thereof to meet the requirements of MIL-PRF-32383/4A.For instance, CWB 10 may be required to flex at least 800 times underload to a 7-inch radius curved surface, such that an edge of the CWB maybe capable of deflecting, in each direction, at least a specifieddistance (i.e., 1 inch) from a centerline of the CWB without sustainingphysical or electrical damage. Accordingly, housing 300 may be able towithstand repeated bending or flexing cycles to allow the CWB to meetthe requirements of MIL-PRF-32383/4A. The housing 300 may include anupper housing or upper shell 310 and a lower housing or lower shell 340that connect to each other to form an interior cavity 302 to receive thebattery cells 20 and other electronics of the conformal wearable battery10. Once the plurality of battery cells 20 and other required componentsare installed inside the interior cavity 302, the upper shell 310 andthe lower shell 340 may be attached to each other with the perimeteredges being sealed together to enable the CWB 10 to meet theenvironmental requirements of MIL-PRF-32383/4A.

To meet these requirements, each shell 310, 340 may be constructed suchthat each shell 310, 340 may bend and flex. In addition to allowing theCWB 10 to bend and flex, the housing 300 may also protect the internalbattery cells 20 and other components to keep the CWB 10 workingproperly. In some examples, each shell 310, 340 may be constructed toinclude rigid regions to strengthen localized area of each shell 310,340 while having some areas that are more flexible to allow housing 300to bend and move. In particular, the upper shell 310 may be formed frommultiple materials and may include a first member 318 formed from afirst material and a second member 326 that is formed from a secondmaterial, and the lower shell 340 may be similarly formed to include afirst member 342 formed from a first material and a second member 350that is formed from a second material. In both of the shells 310, 340,the first material may have a higher stiffness or hardness (i.e.durometer) than the second material. For example, the first material mayhave a durometer of approximately 50 Shore D or greater, or within arange of 40 Shore D and 70 Shore D, or in some cases within a range of30 Shore D and 80 Shore D, while the while the second material may havea durometer of approximately may have a durometer of approximately 70Shore A, or within a range of 55 and 90 Shore A. Accordingly, the secondmember 326, 350 of each shell 310, 340 may bend easier or be moreflexible than its corresponding first member 318, 342. In addition, asdiscussed above, the contact component 130 may be molded into one of theshells 310, 340 in either its corresponding members when the shell isformed. For instance, as illustrated in FIG. 1, the contact component130 may be molded with the first member 342 in the perimeter walls 348of the lower shell 340.

In the illustrated examples of FIGS. 1 and 7-13, the upper shell 310 mayinclude a front wall 312 that forms an exterior or front outward facingsurface 314 of the housing 300 and an interior surface 315 opposite theoutward facing surface 314. The outward facing surface 314 may be formedfrom outward facing surfaces 322 of a plurality of rigid regions 320 ofthe first member 318 and an outward facing surface 330 of the secondmember 326. A perimeter surface 316 may extend from a perimeter of theoutward facing surface 314 towards the interior surface 315. The firstmember 318 may have a plurality of rigid regions 320 that are spacedapart from each other, where the plurality of rigid regions 320 may bearranged in an array with the plurality of rigid regions 320 in both ahorizontal direction and a vertical direction. For example, in theillustrated example of FIG. 7, the rigid regions 320 are arranged in anarray of five columns of rigid regions 320 arranged in a horizontaldirection and four rows of rigid regions 320 arranged in a verticaldirection. The arrangement of the rigid regions 320 may have fewer thanfour rows and five columns or may have greater than four rows and fivecolumns depending upon the desired battery output requirements. Thesecond member 326 may be located between each of the rigid regions 320,such that the second member 326 forms a grid-like structure withvertical regions 328A and horizontal regions 328B that are arranged inthe spaces between the neighboring rigid regions 320. The verticalflexible regions 328A may have a width between neighboring rigid regions320 when measured along the outward facing surface 314 on the front wall312 that is the approximately 10 percent of the width of each rigidregion 320, or within a range of 7 percent and 15 percent of the widthof each rigid region 320. Additionally, the horizontal flexible regions328B may have a height between neighboring rigid regions that isapproximately 14 percent of the height of each rigid region 320, orwithin a range of 10 percent and 20 percent of the height of each rigidregion 320.

As discussed above, the second member 326 may form flexible regionswithin the front wall 312 of the upper shell 310 that promotes bendingwithin these regions while allowing the rigid regions 320 to remainsubstantially planar when the housing 300 is in a deformed state. Inaddition, the thickness of the second member 326 may be substantiallythe same thickness as the rigid regions 320 such that when the housing300 is in an undeformed or unstressed state the outward facing surface330 of the second member 326 may be substantially coplanar with theoutward facing surface 322 of the rigid regions 320. In order to furtherpromote bending within the vertical regions 328A or horizontal regions328B of the second member 326, a plurality of grooves 332 may be locatedwithin the outward facing surface 330 of the second member 326. In someexamples, the grooves 332 may only be located in the outward facingsurface 314, or in other examples, the grooves 332 may be located inboth the outward facing surface 314 and the inward facing surface 315.The grooves 332 in the horizontal regions 328B may have a width that isgreater than a width of the grooves 332 in the vertical regions 328A.For example, the width of the grooves 332 in the horizontal regions 328Bmay be 1.2 to 1.5 times greater than the width of the grooves 332 in thevertical regions 328A. In addition, the grooves 332 in both thehorizontal and vertical regions 328A, 328B may have the same depth, suchthat the grooves 332 may have a constant depth. The width of the grooves332 may be greater than a depth of the grooves 332. For example, thedepth of the grooves 332 may be that is within a range of 50 percent and85 percent of the overall width of the groove 332 to help promoteflexing in the proper locations. In some examples, the depth of thegrooves may be within a range of 2 mm and 4 mm. Alternatively, such asin the housing 300 shown in FIG. 15, the flexible member 326 may notinclude grooves.

Each of the rigid regions 320 may be sized to correspond to the size ofeach of the battery cells. For instance, a length and/or a width of eachrigid regions 320 may be within a range of 0.95 and 1.05 of acorresponding length and/or width of a corresponding battery cell. Inother examples, the length of width of each rigid region 320 may bewithin a range of 0.90 and 1.10 of the corresponding length and/or widthof the corresponding battery cell. In addition, each rigid region 320may be substantially aligned (where the center of the rigid region 320and the center of the battery cell are substantially coaxial with eachother) with the corresponding battery cell located behind it. Each rigidregion 320 may be connected to an adjacent rigid region 320 by a channel324. The channel 324 may help to form a living hinge between the rigidregions 320 and may have a thickness that is less than the thickness ofthe rigid region 320. As illustrated in FIGS. 9 and 13, the channels 324may connect to neighboring rigid regions 320. The channels 324 may alsoassist in manufacturing by providing a pathway for material to flow fromone rigid region 320 to a neighboring rigid region 320 when the firstmember 318 is formed using a molding process. The channels 324 may bevisible along the inward facing surface 315 of the front wall 312.

Additionally, the second member 326 may form the outer perimetersurfaces 316 along with the outer surfaces of the front wall 312 toprovide some flexibility along the outer edges of the upper shell 310.The interior perimeter edges 325 of the upper shell 310 may include areceiver 327 or other feature to mate with a corresponding engagingmember 355 on the lower shell 340. The engaging member 355 may engagethe receiver 327 on the upper shell to help provide a mechanicalconnection to assist with securing the upper shell 310 to the lowershell 340.

As discussed above, the lower shell 340 may connect to the upper shell310 to form the interior cavity 302 that receives the battery cells andother electronics. The lower shell 340 may include a rear wall 341 thatforms an exterior or rear outward facing surface 344 of the housing 300and an interior surface 346 opposite the exterior surface 344. The lowershell 340 may also include a perimeter wall 348 that extends away fromthe exterior surface 344 forming exterior side surfaces 351 and interiorside surfaces 352. The lower shell 340 may be similarly constructed asthe upper shell 310 with a first member 342 and a second member 350. Thefirst member 342 may include a plurality of rigid regions 354, where theplurality of rigid regions 354 may be arranged in an array with theplurality of rigid regions 354 in both a horizontal direction and avertical direction similar to the array of the upper shell 310. Each ofthe rigid regions 354 may be sized to correspond to the size of each ofthe battery cells. The length and width of the rigid regions 354 may besimilarly sized with the rigid regions 320 of the upper shell 310.Similar to the upper shell 310 each rigid region 354 may be connected toan adjacent rigid region 354 by a channel 358. The second member 350 maybe located between each of the rigid regions 354, such that the secondmember 350 forms a grid-like structure with vertical regions 362A andhorizontal regions 362B that are arranged in the spaces between thearray of rigid regions 354. The flexible regions 362A, 362B of thesecond member 350 may promotes bending within these regions whileallowing the rigid regions 354 to remain substantially planar when thehousing 300 is in a deformed state. The length and width of the flexibleregions 362A, 362B may be similarly sized with the flexible regions328A, 328B of the upper shell 310.

In order to further promote bending within the vertical regions 362A orhorizontal regions 362B of the second member 350, a plurality of grooves364 may be located within the outward facing surface 366 of the secondmember 350. In some examples, the grooves 364 may only be located in theoutward facing surface 366 or in other examples, the grooves 364 may belocated in one of or both the outward facing surface 366 and the inwardfacing surface 368 of the second member 350. The grooves 364 may besized similarly to the grooves 332 of the upper shell 310 as describedabove, or may have a different size than grooves 332. Optionally, insome examples, a plurality of ribs 370 may extend from the inward facingsurface 368 of lower shell 340 along the vertical regions 362A. Theseribs 370 may be intermittent and run substantially along a verticallength of each rigid region 354 while being absent across the horizontalregions 362B of the second member 350. In addition, as shown in theillustrated example of FIG. 11, the channels 358 may extend from a firstrigid region 354A to an adjacent rigid region 354B and the channels 358may extend inward may not be planar with the adjacent rigid regions354A, 354B where an inward facing surface 360 of the channel 358 thatconnects from the first rigid region 354A to the second rigid region354B may be further inward than the inward facing surface 357 of each ofthe rigid regions 354A, 354B. Alternatively, as shown in FIGS. 13 and15, the channels 324, 358 may be planar with the inward facing surfaces323, 357 of the corresponding rigid region 320, 354.

Both the upper shell 310 and the lower shell 340 may be formed in asimilar manner. For example, each shell 310, 340 may be formed using aninjection molding process, in particular, each shell 310 may be formedusing a two-shot molding or overmolding technique. Using this process,the first members 318, 342 of each shell 310, 340 may be formed using aninjection molding technique by filling a first mold with the firstmaterial, thereby forming the first member as a single unitary member.The first members 318, 342 may then be removed from the first mold andplaced into a second mold. A second material may then be injected intothe second mold where the second material flows over the first member318, 342 whereby the second member 326, 350 is formed onto itsrespective first member 318, 342 also using an injection moldingprocess. For example, second member 326 is formed onto the first member318 to form the upper shell 310, and second member 350 is formed ontofirst member 342 to form the lower shell 340. In some examples, thefirst mold may have additional slides or components that can be arrangedsuch that the second member 326, 350 may be formed onto itscorresponding first member 318, 342 without removing the first member318, 342 from the first mold and placing it into a second mold.Alternatively, the second members 326, 350 may be molded separately fromtheir corresponding first members 318, 342 and joined using adhesives,welding, or other methods for attachment. Optionally, the first members318, 342 and second members 326, 350 may be stamped, machined, or formedusing other production methods.

The interface between the first member 318, 342 and its correspondingsecond member 326, 350 may be arranged to help secure the memberstogether and to handle the stresses created in this joint to prevent anyseparation between the two members during repeated bending cycles. Asshown in FIGS. 11 and 12, each rigid region 320 may have an edge region333 along the perimeter of that extends between the outward facingsurface 322 and the inward facing surface 323 along a perimeter of eachrigid region 320. This edge region 333 may extend completely around theperimeter of each rigid region 320 except for the areas where thechannel 324 of each rigid region 320 may extend to a neighboring rigidregion 320. The edge region 333 may include a first edge surface 335 anda second edge surface 337, where the first edge surface 335 and thesecond edge surface 337 may extend in different directions. The firstedge surface 335 may extend substantially perpendicular from the outwardfacing surface 322 an end 336 approximately 50 percent of a thickness ofthe rigid region 320. The second edge surface 337 may have a firstportion 338 that extends from end 336 in a direction that issubstantially perpendicular to the first edge surface 335. The secondedge surface 337 may also have a curved portion 339 that connects fromthe first portion 338 to the inward facing surface 323. The secondmember 326 may have a second edge region 334 that has a complementarystructure to the first edge region 333 such that the first member 318and the second member 326 may be substantially coplanar on adjacentsurfaces of the first edge region 333. This edge region 333 may allowthe second member 326 to have a width adjacent the inward facingsurfaces 323 of the rigid regions 320 that is greater than a width ofthe second member 326 adjacent the outward facing surfaces 322 of therigid regions 320. In some examples, the distance across the horizontalflexible regions 328B may be greater than the distance across thevertical flexible regions 328A. Because the width of the horizontalflexible regions 328B may be greater than the width of the verticalflexible regions 328A, the ratio of the width of the second member 326at the horizontal flexible regions 328B adjacent the inward facingsurfaces 323 of the rigid regions 320 may be within a range of 125percent and 160 percent of the width of the second member 326 adjacentthe outward facing surfaces 322 of the rigid regions 320, while theratio of the width of the second member 326 at the vertical flexibleregions 328A adjacent the inward facing surfaces 323 of the rigidregions 320 may be within a range of 170 percent and 200 percent of thewidth of the second member 326 adjacent the outward facing surfaces 322of the rigid regions 320. While the above description uses only thereference numbers and features of the upper shell 310, the edge region374 of the rigid regions 354 may have similar if not identical surfacessuch that the second member 350 of the lower shell 340 may have similardimensions and dimensional relationships as the second member 326.

Alternatively, the interface between rigid member 318 and the flexiblemembers 326 may have different edge geometry along the rigid regions 320to promote a robust and durable joint. For instance, as shown in FIG. 14where the edge region 333 may have a sinusoidal or curved surface onboth the outward facing surface 322 and the inward facing surface 323,such that the flexible member 326 has a corresponding sinusoidal orcurved surface shape, then the flexible member 326 may be formed ontoeach of the rigid regions. As another option, the rigid region 320 mayalso include an opening, such as a hole, that extends either partiallyor completely through the thickness of the rigid region that receivesthe material of the flexible member to help in forming a secure jointbetween the flexible member 326 and the rigid member 318.

As discussed above, the shells 310, 340 utilize rigid members 318, 342and flexible members 326, 350 to form a bendable housing 300. The rigidmembers 318, 342 may be formed by a molding technique such as injectionmolding and may be formed from a material with a greater stiffness orrigidity than a material used to form the flexible members 326, 350. Forinstance, the rigid members 318, 342 may be formed from a first materialthat may be a polymeric material such as polycarbonate (PC),polypropylene (PP), or similar materials known to one skilled in theart. The polymeric material may be a filled or unfilled polymer. Thesecond material may be molded onto the rigid member 318, 342 that formsthe flexible member 326, 350. The second material may be a thermoplasticelastomer (TPE), a thermoplastic urethane (TPU), thermoplasticvulcanizates (TPV), or other similar material. Optionally, the secondmaterial may have a deep red aniline dye colorant that appears black.This aniline dye may be an infrared transmitter that allows the uppershell 310 and the lower shell 340 to be laser welded to permanently jointhe shells 310, 340 together to seal the CWB 10.

FIGS. 16-28 illustrate another exemplary conformal wearable battery(CWB) 50. CWB 50 may include internal battery cells 60 and otherelectronic components such as a battery-charging controller, and acomputing processor to allow the CWB 50 to operate properly similar toCWB 10 described above. These electronic components may be received inan interior cavity 702 of housing 700 to protect the battery cells 60.Also, similar to CWB 10 described above, CWB 50 may bend or move in botha horizontal and/or vertical direction, or bend in some combinationthereof to meet the requirements of MIL-PRF-32383/4A. For instance, CWB10 may be required to flex at least 800 times under load to a 7-inchradius curved surface, such that an edge of the CWB may be capable ofdeflecting, in each direction, at least a specified distance (i.e., 1inch) from a centerline of the CWB 10 without sustaining physical orelectrical damage. Accordingly, housing 700 may be flexible or bendableto be able to withstand repeated bending or flexing cycles to allow CWB50 to meet the requirements of MIL-PRF-32383/4A. The housing 700 mayinclude an upper housing member or upper shell 710 and a lower housingmember or lower shell 750 that connect to each other to form an interiorcavity 702 that receives the battery cells 20 and other electronics ofthe conformal wearable battery (CWB) 50. Once the plurality of batterycells 60 and other required components are installed inside the interiorcavity 702, the upper shell 710 and the lower shell 750 may be joinedtogether along their perimeters to seal the housing 700 to enable theCWB 50 to meet the environmental requirements of at least IP67 or tomeet MIL-PRF-32383/4A requirements.

The upper shell 710 may have a front wall 712 with an outward facingsurface 714, an inward facing surface 716 opposite the outward facingsurface 714, and a perimeter surface 718 may extend from a perimeter ofthe outward facing surface 714 towards the inward facing surface 716. Inaddition, the lower shell 750 may have a rear wall 752 with an outwardfacing surface 754, an inward facing surface 756 opposite the outwardfacing surface, and a plurality of perimeter sidewalls 760, 761, 762,763 that extend from a perimeter of the outward facing surface 754beyond the interior surface 756, where sidewalls 760 and 762 arearranged opposite each other on a top and bottom of the housing 700 andsidewalls 761 and 763 are arranged opposite each other on a first andsecond side of the housing 700.

As discussed above, CWB 50 may provide power to various electricaldevices by transmitting power from the battery cells 60 through aconnector 70 and may be rechargeable through the connector 70 or throughthe contact components 730. Contact components 730 may be electricallyconnected with the battery cells 60 through a conductive region 62 (i.e.flexible circuits or wiring) connected to the battery cells 60 and mayhave similar electrical connections as discussed above regarding contactcomponents 130, such as a conductive element 105 (i.e. a mechanicalfastener) inserted into openings of the conductive regions 62 toelectrically connect the battery cells 60 and the contact components730. The CWB 50 may include a plurality of contact components 730 thateach have an outward facing surface 736 accessible from outside of theCWB 50 of the housing 700 and an inward facing surface 740 that may beconnected with the conductive region 62 to the battery cells 60. Eachoutward facing surface 736 of the plurality of contacts 730 may besubstantially planer with each other, meaning each outward facingsurface 736 may be within a range +/−5 degrees with the outward facingsurface of the neighboring contact 730. In the illustrated example, CWB50 includes four contact components 730, although the CWB 50 may includefewer contacts such as one, two, or three contacts, or greater than fourcontacts like five contacts, six contacts, or more than six contacts.Each of the contact components 730 may be secured to the lower shell 750of housing 700 where the lower shell 750 forms a seal around eachcontact component 730 to prevent ingress of moisture and debris.

As shown in FIGS. 18A-23, lower shell 750 of the housing 700 may includea plurality of contact carrier assemblies 775, where each contactcarrier assembly 775 includes a contact carrier 780 that secures aplurality of contact components 730. In addition, the lower shell 750may also include a connector plate 720 that is configured to receive oneor more connectors 70 that are connected to the battery cells 60. Asshown in the illustrated example, the lower housing 750 may include apair contact carrier assemblies 775, where each contact carrier 780secured two contact components 730. Further, in the illustrated example,each contact component 730 is individually connected to a plurality ofconductive regions 62 that electrically connect the contact components730 to the plurality of battery cells 60. As previously discussed, eachshell 710, 750 of the housing 700 may be formed using a molding process,such as injection molding from a polymeric material that can flex andbend. The lower shell 750 may be formed around each contact carrierassembly 775 (i.e. the contact carrier 780 and its corresponding contactcomponents 730) to secure contact carrier assembly 775 within to thelower shell 750. Each contact carrier 780 may be secured to a sidewall762 of the lower shell 750 between a rear surface 764 of sidewall 762and a rear flange 766 that is spaced rearward of rear surface 764. Asshown in cross-sectional view of FIG. 22, a plurality of plugs 768 mayextend from rear surface 764 of sidewall 762 through openings 786 of thecontact carrier 780 to the rear flange 766 of the lower shell 750. Bylower shell 750 being formed around the contact carrier 780, theplurality of plugs 768, rear flange 766, and the sidewall 762 may be asingle unitary member. As shown in FIG. 21, each rear flange 766 mayinclude an opening 770 that extends from a rear surface 772 of the rearflange 766 to enable access to an inward facing surface 740 of a contactcomponent 730. Each opening 770 may have a slightly greater width than awidth of the conductive regions 62 and conductive element 105 thatconnect to the inward facing surface 740 and also align each conductiveregion 62 such that it may be easily connected to its correspondingcontact component 730.

The lower housing 750 may also be formed around the connector plate 720to secure the connector plate 720 to the lower housing 750. Forinstance, the connector plate 720 may have a front surface 722, a rearsurface 724 opposite the front surface, and a plurality of openings 726extending through the front and rear surfaces 722, 724. The connectorplate 720 may have a connector opening or plurality of connectoropenings 728 to receive a connector 70 from the battery cells 60.Similar to the contact carrier(s) 780, the lower shell 750 may be formedaround the connector plate 720 and may be secured to a sidewall 761 ofthe lower shell 750 between a rear surface 765 of sidewall 761 and arear flange 767 that is spaced rearward of rear surface 765. Inaddition, a plurality of plugs may extend from rear surface 765 ofsidewall 761 through an opening 726 of the connector plate 720 to therear flange 767 of the lower shell 750.

To enhance the upper and lower shells 710, 750 ability to bend, theupper and lower shells 710, 750 may include a plurality of verticallyand horizontally intersecting grooves 755. The grooves 755 may belocated within the front walls 712, 752 of the respective shells 710,750. In some examples, the grooves 755 may be located in the outwardfacing surfaces 714, 754, and may have corresponding inward protrusions757 that extend from inward facing surfaces 716, 756 of the respectiveupper and lower shells 710, 750. The grooves 755 may be arranged in thespaces that are between the individual battery cells within the array ofbattery cells 60. The grooves 755 may be arranged in both a verticaloriented grooves 755A and horizontal oriented grooves 755B. Thehorizontal grooves 755A may have a width that is greater than a width ofthe vertical grooves 755B. For example, the width of the horizontalgrooves 755B may be 1.2 to 1.5 times greater than the width of thevertical grooves 755A. In addition, the vertical and horizontal grooves755A, 755B may have the same depth, such that the grooves 755 may have aconstant depth. The width of the grooves 755 may be greater than thedepth of the grooves 755. For example, the depth of the grooves 755 maybe that is within a range of 50 percent and 85 percent of the overallwidth of the groove 755 to help promote flexing in the proper locations.In some examples, the depth of the grooves 755 may be within a range of2 mm and 4 mm. In addition, both of the upper and lower shells 710, 750may also include a plurality of substantially rectangular shaped pockets759 may be located in a grid-like pattern that substantially matches thelayout of the plurality of battery cells 60.

As shown in FIGS. 24-25, each contact carrier assembly 775 may include acontact carrier 780 and a pair of contact components 730. Each contactcarrier assembly 775 may be formed separately from the lower shell 750using a molding process. In some examples, the contact components 730may be placed in a mold where the contact carrier 780 is formed at leastpartially around a rear portion 734 of each contact component 730 tosecure the contact component 730 to the contact carrier 780.Alternatively, each contact carrier 780 may be formed separately fromthe contact components 730, and the contact components 730 beinginstalled into the contact openings 790 of the carrier 780 to form thecontact carrier assembly 775. For instance, the contact components 730may be installed using an adhesive, heat staking, ultrasonic welding, orother process known to one skilled in the art. In this manner, eachcontact component 730 may be integrally joined to its respective contactcarrier 780 to form a mechanical lock securing contact component 730 toits respective carrier 780 making these components integrally joinedsuch that such that separation of the joined pieces cannot beaccomplished without structural damage to either the carrier 780 and/orcontact components 730.

Each contact carrier 780 may include features to ensure the properalignment of the contact components 730 and to secure the carrier 780 tothe lower shell 750. For instance, each contact carrier 780 may have afront surface 782, a rear surface 784 opposite the front surface 782, asidewall surface 785 extending between the front surface 782 and therear surface 784, and a plurality of openings 786, at least one contactopening 790, a plurality of alignment apertures 788 on the rear surface784 above the contact openings 790, an engaging member 792 extendingfrom the front surface 782, and a recess 794 extending around theengaging member 792 below the front surface 782. The engaging member 792may have a tapered outer surface such that when the lower shell 750 isformed around the engaging member 792, a corresponding tapered surface774 is formed in the lower shell 750. This pair of tapered surfaces mayfurther help to secure the carrier 780 within the shell 750 to preventany movement of the contact components 730 during use. Alternatively,the engaging member 792 may have an outer surface that is orthogonal tothe front surface 782. In addition, recess 794 may allow a correspondingprotrusion 776 to be formed within the recess to help secure the carrier780 in shell 750. As discussed above, the contact carrier 780 may have aplurality of openings 786. As shell 750 is formed around carrier 780,the material forming shell 750 may flow through each of the openings 786to form a mechanical lock securing the carrier 780 to shell 750 makingthese components integrally joined. Each opening 786 may be acylindrical hole or may be a truncated conical shape such that the innerwall has a taper, or may be a different geometric shape. In theillustrated example, the openings 786 are symmetrically arranged about acenter plane of the carrier 780, although in other examples, theopenings 786 may be asymmetrically arranged. Further, the openings 786may all be the same size or may have different shapes. For instance, theopenings 786 may be larger on an upper portion of the carrier 780 than abottom portion of the carrier 780 or may be larger on a bottom portionthan an upper portion, or may be larger on a left side than a rightside, or may be larger on a right side than a left side. The alignmentaperture 788 may help to align and secure the contact carrier 780 withina mold when the lower shell 750 is formed. The alignment aperture 788may engage a corresponding feature within the mold to secure the contactcarrier assembly 775 within the mold to ensure proper alignment of thecontact components 730.

Each contact component 730 may have a front portion 732 and a rearportion 734, where the front portion 732 includes the outward facingsurface 736 and a forward perimeter region 738 surrounding the outwardfacing surface 736, and the rear portion includes the inward facingsurface 740, a rear perimeter region 742 surrounding the inward facingsurface 740, and an opening 744 on the inward facing surface 740. Inaddition, the forward perimeter region 738 of each contact component 730may be secured to sidewall 762 of lower shell 750 to form a sealed edgeto prevent ingress of liquids into the interior cavity 702 to protectthe electronic components and prolong the life of the battery cells 60.In some examples, each contact component 730 may be encased by differentmaterials. For instance, as shown in FIG. 23, the forward perimeterregion 738 may be partially or fully encased within sidewall 762 of thelower shell 750, where sidewall 762 is formed from a first material andthe rear perimeter region 742 may be partially or fully encased withincontact carrier 780 that is formed from a second material. The firstmaterial may have a lower stiffness or lower hardness than the secondmaterial. For example, the first material (i.e. the material formingshells 710, 750) may be a rubber or elastomeric material. For example,the first material (i.e. for the shells 710, 750) may be thermoplasticvulcanizates (TPV), a thermoplastic elastomer (TPE) such as athermoplastic elastomeric olefin (TEO), or other similar material. Thesecond material (i.e. the material of the contact carrier 780) may be amore rigid polymeric material, such as a polycarbonate (PC) orpolypropylene (PP). For example, the first material forming the shells710, 750 may have a durometer of approximately 70 Shore A, or within arange of 55 and 90 Shore A, while the second material forming thecontact carrier 780 may have a durometer of approximately 50 Shore D orgreater, or within a range of 40 Shore D and 70 Shore D, or in somecases within a range of 30 Shore D and 80 Shore D. This combinationprovides an elastomeric material around the outboard portion 732 to helpwith sealing, while the more rigid carrier 780 provides a support to therear portion 734 to keep the contacts 730 aligned and prevent anycontact movement when the contacts 730 are connected to a charger.

As shown in FIGS. 26A-27D, the contact component 730 may have multiplefeatures to help secure and seal the contact component 730 to both thelower shell 750 and contact carrier 780. Both the forward and rearportions 732, 734 may have a generally cylindrical in shape. Although,these portions 732, 734 may have any geometric shape while stillproviding adequate surface area to make an electrical connection. Theforward portion 732 may have a larger diameter than the rear portion734. In addition, the forward perimeter region 738 may have a groove 746that extends around the entire forward perimeter region 738. The groove746 may have a width, W1, which is approximately 50 percent of thelength, L1, of the forward portion 732, or within a range of 25 percentand 75 percent of the length, L1. The groove 746 may also have a depthof approximately 50 percent of the width, W1, or within a range of 25percent and 75 percent of the width, W1. While the contact component 730illustrated in FIGS. 26A through 27D has only a single groove 746, otherexemplary contact components 730 may have a plurality of concentricgrooves 746. Still other exemplary contact components 730 may have adifferent texture or contours along the forward perimeter region 738such as knurling, longitudinal or angled gear teeth, or other similartexturing. The rear portion 734 may have a textured region 748 aroundthe rear perimeter region 742 that in some examples may be anarrangement of angled or helical gear teeth. The gear teeth extend alonga majority of the rear perimeter portion 742 and may also extend intothe inward facing surface 740. The gear teeth 748 may be arranged at anacute angle to the inward facing surface 740. In some examples, theacute angle may be greater than zero to provide a bearing surface at anangle to any type of direct pullout force. The angled teeth also help tosecure against any rotation of the contact component 730 in the contactcarrier 780. In some examples, as an alternative to gear teeth, thetextured region 748 may include knurling, grooves, or some combinationof the textures. The rear portion 734 may have a length, L2, which isover two times greater than the length, L1, the forward portion 732.Opening 744 may be configured to receive conductive element to connectthe flexible circuit 62 to the contact component 730, which may be amechanical fastener. In this example, the opening 744 may have femalethreads such that when the mechanical fastener is inserted into theopening 744, an electrical connection between the contact component 730and battery cells 60 is made while also providing a mechanicalconnection between them. The diameter of the outer facing surface 736may be within a range of 0.29 inches and 0.31 inches, or in someexamples, may be within a range of 0.25 inches and 0.35 inches.

FIG. 28 illustrates an exemplary method for forming the housing 700 forCWB 50 and assembling the battery cells 60 into the housing. Inoperation 805, the contact components 730 may be formed using amachining, forging, stamping, or other processes known to one skilled inthe art. The contact components 730 may be formed from a conductivematerial, such as a brass, gold, copper, silver, aluminum, steel, orother electrically conductive material or combination of one or moreelectrically conductive materials. The connector plate 720 may be formedfrom a metallic or non-metallic material and may be formed using amachining, forging, molding, stamping, or other process known to oneskilled in the art.

In operations 810 and 815, the contact components 730 may be insertedinto a first mold configured to form the contact carrier 780. Thecontact carrier 780 may be formed using a molding process such asinjection molding from a non-metallic material. The contact carrier 780may be formed from a polymeric material as described above that may astiffness that is greater than the stiffness of the material that formsthe shells 710, 750. For example, the material forming the contactcarrier 780 may have a modulus (i.e. stiffness) that is 1.5 timesgreater than a modulus (i.e. stiffness) of the material forming thelower shell 750 (or upper shell 710). Because the contact carrier 780may be formed from a rigid impact absorbing material, the contactcarrier 780 may be easier to hold within the mold. With the contactcomponents 730 installed within the mold, the contact carrier 780 isformed within the mold. As the contact carrier 780 is formed, thematerial forming the contact carrier 780 flows around the rear portion734 of each contact component 730 including between the helical gearteeth 748 to form a mechanical lock around the rear portion 734 of eachcontact component 730 to secure them to the contact carrier 780.

In operations 820 and 825, after removing contact carrier 780 from thefirst mold, the contact carrier 780 and a connector plate 720 may beinstalled into a second mold. The lower shell 750 is then formed usinginjection molding or similar type process from a non-metallic materialdifferent from the material of the contact carrier 780. As the lowershell 750 is formed, the material forming the lower shell 750 flowsaround the contact carrier 780 forming the rear flange 766 and also theplugs 768 may be formed by flowing through the openings 786 to securethe contact carrier(s) 780 to the lower shell 750. Similarly, as thelower shell 750 is formed, the material forming the lower housing 750may flow around the connector plate 720 to secure the connector plate720 to the lower housing 750.

In operations 830 and 835, the upper shell 710 may be formed usinginjection molding or similar type process from the same or similarmaterial similar forming the lower shell 750 in a third mold. Next, thebattery cells 60 may be installed into the lower housing 750. Aconnector 70 from the battery cells 60 may be inserted into an openingof the connector plate 720 and then secured to the connector plate 720.In addition, the battery cells 60 may be electrically connected througha conductive element 105 (i.e. a mechanical fastener) inserted intoopening 744 of each contact component 730. As shown in FIG. 18B, thebattery cells 60 may include a plurality of flex circuits 62 that haveconductive features such that each flex circuit 62 may receive aconductive element to provide an electrical connection between thebattery cells 60 and each contact component 730.

Lastly, in operation 840, the upper shell 710 may be attached to thelower shell 750 along with the two shells 710, 750 being sealed togetherto help the CWB 50 meet the environmental requirements. In someexamples, the upper shell 710 and/or the lower shell 750 may have asecond polymeric material molded along the perimeter of either or bothshells 710, 750 that has a dye, such as a deep red aniline dye, thatcauses the material to be an infrared transmitter This second materialmay allow the upper shell 710 and the lower shell 750 to be laser weldedto permanently join the shells together to seal the CWB 50.

In the following description of various illustrative arrangements,reference is made to the accompanying drawings, which form a parthereof, and in which is shown, by way of illustration, variousarrangements in which aspects of the disclosure may be practiced. It isto be understood that other arrangements may be utilized, and structuraland functional modifications may be made, without departing from thescope of the present disclosure.

It is noted that various connections between elements are discussed inthe following description. It is noted that these connections aregeneral and, unless specified otherwise, may be direct or indirect, andthat the specification is not intended to be limiting in this respect.

A rechargeable conformable wearable battery (CWB) assembly may be wornby a user to power electronic devices that the user carries. The CWBassembly may be subjected to environmental conditions that the user isalso subjected to. A sealed housing and a reliable seal may facilitatelonger battery life and utility for the user regardless of environmentalconditions that the CWB may be subjected to. To provide a desired poweroutput, the CWB assembly may include a plurality of battery cells, eachwith a rated power capacity and when electrically connected, may allowthe CWB to provide a desired power output.

A CWB assembly may include an array of a first quantity of battery cellsdisposed adjacent to one another in a horizontal direction and a secondquantity of battery cells disposed adjacent to one another in a verticaldirection. The array of battery cells may be arranged in a grid-likepattern. Each of the battery cells may be encased or housed in a batterycell housing separate from other battery cells. A battery cell asdescribed herein may include a plurality of individual battery cellelements that are electrically connected together to form a compoundbattery cell that electrically performs as a single unit. Each of thebattery cell housings may be physically connected to adjacent batterycell housings by flexible elements (e.g., a flexible printed circuitboard), thereby facilitating a surface outline or shape of the array ofbattery cells to generally conform to a surface outline or shape of auser wearing the CWB assembly. One or more of the battery cell housingsmay include a positive-charge electrical terminal and a negative-chargeelectrical terminal that are electrically connected with the batterycell within an interior of the battery cell housing and provideelectrical power to electrical devices disposed exterior to the batterycell housing. Electrical terminals of a plurality of the battery cellsin the array of battery cells may be connected together to routeelectrical current through the plurality of the battery cells and a setof positive-charge and negative-charge electrical terminals that areshared among the plurality of the battery cells. The positive-chargeelectrical terminal and the negative-charge electrical terminal mayprovide an electrical current that passes through an electricallyconductive path, for example, through an electronic device, via transferof electrons through the electrically conductive path between thepositive-charge electrical terminal and the negative-charge electricalterminal on the exterior of the battery cell housing. The CWB assemblymay include a set of positive-charge and negative-charge electricalterminals that are shared among the plurality of the battery cells ofthe array of battery cells. The plurality of the battery cells may beelectrically coupled together, for example, in series or in parallel.

The battery cell housing may be formed of a molded casing. The moldedcasing may be a sealed case that is formed by a molding process, forexample, an injection molding process. The molded casing may be formedof a plastic material, for example. The casing may be sealed to preventingress of solid material and/or liquid material, for example, accordingto an IP67 rating, IP68 rating, or other ingress protection rating. Thecasing may feature a seam between two halves of the casing that issealed to encase the battery cell within the casing. The positive-chargeterminal and the negative-charge terminal may each include a conductiveregion that passes between the interior of the cell housing and theexterior of the cell housing at a seam of the casing. The conductiveregion may be affixed and electrically connected to the battery cell inan interior of the cell housing at one end, pass through the sealed seamof the casing, and affix to a contact component that electricallycouples with electrical devices at an exterior of the cell housing.

Electrical terminals of a plurality of the battery cells in the array ofbattery cells may be connected together to route electrical currentthrough the plurality of the battery cells and a set of positive-chargeand negative-charge electrical terminals that are shared among theplurality of the battery cells. The positive-charge electrical terminaland the negative-charge electrical terminal may provide an electricalcurrent that passes through an electrically conductive path, forexample, through an electronic device, via transfer of electrons throughthe electrically conductive path between the positive-charge electricalterminal and the negative-charge electrical terminal on the exterior ofthe battery cell housing. The CWB assembly may include a set ofpositive-charge and negative-charge electrical terminals that are sharedamong the plurality of the battery cells of the array of battery cells.The plurality of the battery cells may be electrically coupled together,for example, in series or in parallel.

The battery cell housing may be formed of a molded casing. The moldedcasing may be a sealed case that is formed by a molding process, forexample, an injection molding process. The molded casing may be formedof a plastic material, for example. The casing may be sealed to preventingress of solid material and/or liquid material, for example, accordingto an IP67 rating, IP68 rating, or other ingress protection rating. Thecasing may feature a seam between two halves or portions of the casingthat is sealed to encase the battery cell within the casing.

The positive-charge terminal and the negative-charge terminal may eachinclude a conductive region that passes between the interior of the cellhousing and the exterior of the cell housing at an outer wall of thecasing. The conductive region may be affixed and electrically connectedto the battery cell in an interior of the cell housing at one end, passthrough the sealed wall of the casing, and affix to a contact componentthat electrically couples with electrical devices at an exterior of thecell housing.

In some cases, the CWB assembly may be provided in a form factor easilycarried by a person, such as within a pocket or with other means ofsecuring the CWB assembly to a person's clothing, uniform, or the like.To provide the specified power output, while also providing flexibilityfor conforming to a shape of person's body or equipment when carried,the matrix of battery cells may be arranged on, and affixed to, aflexible printed circuit board. To fit within the housing of the CWBassembly, the flexible printed circuit board assembly may be configuredto be folded along an axis (e.g., a center line), such that battery cellmodules may be on an exterior surface of the flexible printed circuitboard assembly closest to the housing, while the electrical connectionsmay be made on an interior surface of the folded printed circuit boardassembly. An electrical insulator (e.g., foam, insulating tape, etc.)may be placed between the folded sections to provide electricalinsulation for the electrical contacts.

FIG. 29 shows a first view of an illustrative flexible printed circuitboard (PCB)1100 for an illustrative conformal wearable battery systemaccording to aspects of the present disclosure. The flexible PCB may beconfigured to provide power and/or electrical signals from a pluralityof battery cells and/or other components of a CWB. The flexible PCB 1100may be formed of one or more layers of a flexible polymer or plasticmaterial, such as a polyimide or other such flexible substrate. In somecases, markings showing locations of placement of battery cells may beformed through a silk-screening process, or other like method. In somecases, markings may not be present on a surface of the flexible PCBA.Electrical conductors may be included in one or more layers of theflexible PCBA. In some cases, electrical conductors may be configured asa conductive pattern (e.g., a copper overlay, a conductive ink, etc.) onthe surface of the substrate of the flexible PCB 1100. In some cases,exposed conductive features (e.g., conductors, a bare copper surface, abare aluminum surface, etc.) may be coated with a coverlay substance,such as an electrical insulator. For conductive portions of the flexiblePCB not covered with a coverlay, the surface may be plated, such as withan electroless nickel immersion gold (ENIG) finish, a lead-freeimmersion silver finish or other substances with improved conductiveproperties.

The flexible PCB 1100 may be configured to bend along a bend line 1105located at or near a center line of the flexible PCB 1100. One or moreelongated cut-outs may be disposed parallel to the bend line 1105 (e.g.,cut-out 1110) and/or perpendicular to the bend line 1105 (e.g., cut-out1120), where the cut-outs perpendicular to the bend line 1105 may bealigned with a flex line 1125 perpendicular to the bend line 1105. Insome cases, the flex line may correspond to a section of the flexiblePCB 1100 located between rows of components (e.g., battery cells) alongwhich the CWB may bend during use. Such cut-outs may provide additionalflexibility to the flexible PCB 1100 to allow for easier formation of a180-degree bend such as by folding the right half of the flexible PCB1100 over the left half of the flexible PCB 1100. In the illustrativeexample, relief cuts, such as the cut-out 1110 may be formed as arounded elongated rectangular cutout and the cut-out 1120, may be formedin a generally obround shape (e.g., two substantially semi-circularsections connected by a rectangular section). As mentioned, theelongated rounded rectangular cut-outs (e.g., cut-out 1110) parallel tothe bend line 1105 may reduce stress on the plastic substrate whenforming the about 180-degree bend. Additionally, the obround-shapedcut-outs (e.g., cut-out 1120) may reduce stresses placed on the flexiblePCB substrate during use, such as by reducing stresses along a line ofdeformation (e.g., the flex line 1125) between battery cells. In somecases, additional cut-outs may be included to reduce stresses along theflex line, such as at an edge of the flexible PCB 1100, such as a cornernotch 1190 a located near a corner formed in the edge of the flexiblePCB 1100 near a flex line and/or a notch 1190 b located along an edge ofthe flexible PCB 1100 and aligned near a flex line. By reducing thebending stress at locations along the bend line, a probability of acatastrophic failure of the substrate (e.g., cracking, delamination, andthe like) is reduced. While cut-out 1110 is shown as a roundedrectangular shape and the cut-out 1120 is shown as an obround shape,other shapes may be used to reduce stress due to bending and/or flexingof the flexible PCB 1100. While an obround shape is shown on theillustrative example, other cut shapes may be used to achieve a same orsimilar purpose. Such other shapes may include circular cuts which maybe used, for example, for removing more weight, oval cuts which mayprovide additional stress relief, for example, based on the curves,elongated slots which, for example, may be similar to the rectangularcuts but with even more filet on corners to reduce additional stresses,a dog-bone shape (e.g., two substantially circular sections connected bya rectangular section, or the like.

The flexible PCB 1100 may also include a plurality of solder pads (e.g.,pads 1150) to provide electrical connection for the cathode and anode ofeach battery module. For battery cells located near an edge of theflexible PCB 1100, the cathode an anode connectors may be bent over theedge of the flexible PCB 1100. For battery cells located away from theedge of the flexible PCB, a plurality of cut-outs (e.g., cut-out 1140)are located near a corresponding pad 1150 to allow for solder or weldconnection of the battery cathode or anode connector to the flexible PCB1100. Additionally, the flexible PCB 1100 may include chargingconnection portion 1190 that may be used to connect to one or morecharging tabs on an exterior portion of a case of the conformal wearablebattery enclosure and/or a flexible connector portion 1160 that mayinclude one or more flexible connectors to connect to additionalcircuitry, such as a control module, a display module, or the like). Theflexible PCB 1100 may also include one or more semi-circular cut-outsections 1170 to provide an area of low mechanical stress at an interiorportion of the flexible PCB 1100. In some cases, an electrical component1280, shown in FIG. 30, (e.g., a thermistor) may be physically connectedto the flexible PCB 1100 in this area such that the electrical componentdoes not receive stress loads while the CWB is flexed during use. Suchstress loads, without the stress relief provided by the semi-circularcut-outs, may cause the electrical component to detach from the flexiblePCB 1100.

FIG. 30 shows second view of the illustrative flexible printed circuitboard 1100 for the illustrative conformal wearable battery systemaccording to aspects of the present disclosure. In some cases,connection locations for each battery cell may be marked. Additionallyor alternatively battery cell connection locations may include arigidizing material, or may be otherwise reinforced. Each battery celllocation 1230 may be associated with a pair of cut-outs for the anodeand cathode connections, as discussed above. Here, a battery cell modulemay be physically attached to the substrate of the flexible PCB 1100,such as by use of an adhesive material (e.g., glue, tape, etc.). Thecathode and anode connection tabs may be inserted through acorresponding cut-out 1140 so that the connection tabs may be soldered,laser welded, or otherwise connected to the connection pad 1150 on theother side of the flexible PCB 1100.

The electrical connection cut-outs (e.g., cut-out 1140) and/or end cutouts (e.g., cut-out 1190 a, 1190 b) may be disposed near or offset froma flex line 250 between rows of battery cell locations 1230 at adistance configured to reduce or eliminate stresses applied to the celltabs (e.g., a cathode connection tab, an anode connection tab) of eachbattery cell. Because the battery cell locations are reinforced orotherwise stiffened by the battery modules, the flex lines 1250 allowfor the CWB to be flexed within a designed range of motion, when in use.To provide stress relief along these flex lines between the rigidbattery cell portions, the obround-shaped cut-outs 1120 are disposedwithin each flex line 1250 and may be aligned with a portion of thebattery cell connection cut-outs (e.g., cut-out 1140) and the edgecut-outs 1190 a, 1190 b may be aligned to the flex lines 1250 andlocated at an edge of the flexible PCB 1100.

FIG. 31 shows a partial second view of the illustrative flexible printedcircuit board 1100 including cut-outs providing strain relief along acenter line and/or along a flex line perpendicular to the center lineaccording to aspects of the present disclosure. As discussed above, therectangular cut-out 1110 may be disposed centered on and parallel to thebend line 1105 at the center of the flexible PCB 1100, where at least aportion of the cut-out 1110 may be disposed underneath a battery cellmodule when installed. In an illustrative example, a battery cellconnection area 1330 may be about 50 mm in length, where the cut-out1110 may be located near a mid-point of the battery cell connection area1330. In an illustrative example, a first edge 1312 a of the cut-out1110 may be located at a first distance (e.g., about 11.5 mm, about 12mm, etc.) from a first edge of the battery cell connection area 1330,the second edge 1312 b of the cut-out 1110 may be located at a seconddistance (e.g., about 11.5 mm about 10 mm) from the second edge of thebattery cell connection area 1330, and the length of the cut-out 1110between the first edge 1312 a and the second edge 1312 b may be a firstdimension (e.g., about 25 mm, about 28 mm, or the like). In some cases,cut-outs of a similar type may have different sizes and/or relativelocations. A width of the cut-out between the left edge 1314 a and theright edge 1314 b may be a second dimension (e.g., about 4.5 mm), and aradius of each rounded corner 1316 may be a third dimension (e.g., about1.1 mm). The specific distances and/or dimension are given forillustrative purposes and other distances and/or dimensions may becontemplated within the scope of this disclosure.

The illustrative obround-shaped cut-out 1120 may be formed as arectangular area 1322 b (e.g., a rectangular area of about 2.2 mm×about5 mm) connecting two semi-circular areas 1328 a and 1328 b (e.g.,semicircular areas having a diameter of about 5 mm). For example, theobround-shaped connector 1120 may be centered on and perpendicular tothe bend line 1105. The rectangular area 1322 b may larger than thedistance between adjacent battery cell connection areas. Eachsemi-circular area 1328 a and 1328 b may overlap at least a portion ofadjacent battery connection areas.

The illustrative battery connection cut-out 1140 may be formed as anelongated oval shape, such as an illustrative shape of about 1.5 mm highand having a distance of about 6 mm between a center point of eachcircular end portion (e.g., 1344) and an overall length of about 9 mm.In some cases, a second edge 1342 of the cut-out 1140 may align with acenter line through the obround shaped cut-out 1120. Additionally, theobround-shaped cut-out 1120 may be located a distance (e.g., about 4 mm)from the battery connection cut-out 1140.

FIG. 32 shows a first view of the illustrative flexible printed circuitboard 1100 folded along the bend line 1105 according to aspects of thepresent disclosure. For example, a 180-degree bend 1405 may be formedalong the bend line 1105, such as when a left half of the flexibleprinted circuit board 1100 is folded over a right half of the flexibleprinted circuit board 1100 such that the battery modules are located onthe exterior portion of the folded flexible printed circuit board 1100and the electrical connections for the battery modules are disposed onan interior portion of the folded flexible printed circuit board 1100.FIGS. 33, 34, 35, and 36 show a partial side view of a magnified view ofthe flexible printed circuit board 1100 when folded along the bend line1105 according to aspects of the present disclosure. As can be seen, adiameter of the bend 1405 corresponds the length of the rectangularportion of the obround-shaped cut-out 1120. In the illustrative example,the diameter of the bend 1405 is about 2.25 mm.

FIGS. 37A and 37B show first views of a flexible printed circuit boardassembly (PCBA) 1900 and 1900′ before folding along the bend lineaccording to aspects of the present disclosure. As can be seen, cathodetabs and anode tabs extend from corresponding battery cell modulesthrough a cut-out 1140 so that each tab 1940 may be soldered, welded, orotherwise connected to the electrical connection pad 1150 forming anelectrical connection for each battery cell. To protect against shortcircuits and/or to provide additional protection and/or structuralintegrity for the CWB, while maintaining flexibility, an insulatingmaterial 1954 (e.g., a polymeric material, a foam, etc.), may be placedover a first half of the flexible PCBA 1900 before folding and/or asecond insulating material 1952 may be placed over one or more of thetabs 1940 that may be bent around an edge of the flexible PCBA 1900. Insome cases, the first insulating material 1954 may include a pluralityof cut-outs (e.g., cut-out 1964, cut-out 1962) that may align withsimilar cut-outs on the flexible PCBA 1900′ (e.g., cut-out 1190 a,cut-out 1190 b, cut-out 1120, etc.). The first insulating material mayhave a cut-out section such that a portion of the first insulatingmaterial 1954 may not overlap areas of the flexible PCBA 1900′corresponding to an electrical circuit and/or a connector. In somecases, the second insulating material 1952 may be a flexible material, asemi-flexible material electrically insulating material that may be bentaround an edge of the flexible PCBA 1900 or 1900′ such that at least anedge or another portion of the second insulating material is adjacent anopposite side of the flexible PCBA 1900. The first insulating material1954 may be the same material or a different material than the secondinsulating material 1952.

FIGS. 38A and 38B show second views of the flexible printed circuitboard assembly 1900, 1900′ before folding along the bend line accordingto aspects of the present disclosure. Here an array of battery cells2010 may be physically and electrically attached to the flexible PCBA1900 and flexible PCBA 1900′. FIG. 39 shows a partial first view of theflexible printed circuit board assembly showing the location of thecut-out 1110 and the cut-out 1120 with respect to battery cell modules2010, when installed. FIG. 40 shows a side view of the flexible PCBA1900 before folding along the bend line according to aspects of thedisclosure and FIG. 41 shows a side view of the flexible PCBA 1900 afterfolding along the center line according to aspects of the disclosure.FIGS. 42A and 42B show first views of the flexible printed circuit boardassembly 2400 and 2450 after folding along the bend line according toaspects of the disclosure.

FIG. 43 shows a partial side view of the flexible PCBA 1900′ afterfolding along the bend line and FIG. 44 shows a partial first view ofthe flexible PCBA 1900′ after folding along the bend line according toaspects of the disclosure.

FIG. 45 shows a view of another flexible printed circuit board 1700 foran illustrative conformal wearable battery system according to aspectsof the present disclosure, where the configuration of the flexible PCB1700 is similar to that of the flexible PCB 1100, where differences areprimarily noted in a configuration of the charging connection portion1180 and the flexible connector portion 1160. FIG. 46A shows a foldedconfiguration of the flexible printed circuit board of FIG. 45 accordingto aspects of the present disclosure. FIG. 46B shows a view of theillustrative flexible connection portion 1160 in a folded configurationand FIG. 46C shows a view of the illustrative charging connectionportion 1180 of the flexible printed circuit board 2700 according toaspects of the present disclosure.

The flexible PCB 1100 with the rectangular and/or circular cuts mayallow for an improved manufacturable bend along the bend axis 1105. Inaddition, the flexible PCB 1100 allows for an improved configuration forthe connection of a plurality of cells (e.g., 36 cells) in as flat apattern as possible and within a minimized area, while maintainingflexibility. Generally, printed circuit boards such as the flexible PCB1100 are not useful for other battery packs, particularly if the otherbattery pack does not have to be flexible. A main advantage to thedisclosed flexible PCB 1100 is that the flexible PCB 1100 allows foreasy connection of each cell, both physically and electrically to theflexible PCB 1100, while allowing a finished product incorporating theflexible PCB 1100 (e.g., a conformal wearable battery) to meet or exceedflexibility requirements defined for the conformal wearable battery.FIG. 46D shows a view of the illustrative flexible printed circuit boardof FIG. 42B according to aspects of the disclosure. The flexible printedcircuit board assembly 2450 may include one or more circuit protectioncomponents (e.g., circuit enclosure 2810, circuit enclosure 2820) thatmay be used to enclose electrical circuit components of the CWB. Thecircuit enclosure 2810 and the circuit enclosure 2820 may be constructedof a rigid or semi-rigid material capable of providing mechanicalprotection to the electrical circuit components. Additionally, thecircuit enclosure 2810 and/or the circuit enclosure 2820 may beconstructed of an electrically conductive material (e.g. aluminum,steel, copper, a conductive polymeric material, a foil covered plastic,etc.) that may provide electromagnetic interference (EMI) protection forthe CWB. Each of the circuit enclosure 2810 and/or the circuit enclosure2820 may be physically and/or electrically connected to the flexiblePCBA 2450. For example, one or more clips may be used to mechanicallyattach one or both of the circuit enclosure 2810, 2820 to the flexiblePCBA 2450. In some cases, one or more or the clips may be an EMI clip2840 made of a conductive material that may additionally facilitate anelectrical connection between the circuit enclosure 2810, 2820 to anelectrical ground (e.g., a ground plane) of the flexible PCBA 2450. Insome cases, at least one EMI clip 2840 may be positioned on each side ofthe connected circuit enclosure 2810, 2820. In some cases, a circuitenclosure (e.g., circuit enclosure 2820) may include a cut-out portion2830 to facilitate an electrical connection from an electrical connectoron the flexible PCBA 2450 to an additional component of the CWB, such asan input/output module (e.g., a display module) capable of providingstatus information from a controller of the CWB to a user of the CWB. Insome cases, the circuit enclosure 2810, 2820 may be of a similar sizeand/or shape (e.g., similar dimensions) to that of a battery cell.

FIGS. 47A-47D show illustrative views of an illustrative flexible PCB2900 according to aspects of the disclosure. FIG. 47A shows a first viewof an illustrative flexible printed circuit board (PCB) 2900 for anillustrative conformal wearable battery system according to aspects ofthe present disclosure. The flexible PCB 2900 may be configured toprovide power and/or electrical signals from a plurality of batterycells and/or other components of a CWB. The flexible PCB 2900 may beformed of one or more layers of a flexible polymer or plastic material,such as a polyimide or other such flexible substrate. In some cases,markings showing locations of placement of battery cells may be formedon a surface of the flexible PCB, such as through a silk-screeningprocess, or other like method. Electrical conductors may be included inone or more layers of the flexible PCBA. In some cases, no markingsshowing battery placement may be present. In some cases, electricalconductors may be configured as a conductive pattern (e.g., a copperoverlay, a conductive ink, etc.) on the surface of the substrate of theflexible PCB 2900. In some cases, exposed conductive features (e.g.,conductors, a bare copper surface, a bare aluminum surface, etc.) may becoated with a coverlay substance, such as an electrical insulator. Forconductive portions of the flexible PCB not covered with a coverlay, thesurface may be plated, such as with an Electroless nickel immersion gold(ENIG) finish, a lead-free immersion silver finish or other substanceswith improved conductive properties.

The flexible PCB 2900 may be configured to bend along a bend line 1105located at or near a center line of the flexible PCB 2900. One or moreelongated cut-outs may be disposed parallel to the bend line 1105 (e.g.,cut-out 1110) and/or perpendicular to the bend line 1105 (e.g., cut-out2920). Such cut-outs may provide additional flexibility to the flexiblePCB 2900 to allow for easier formation of a 180-degree bend such as byfolding the right half of the flexible PCB 2900 over the left half ofthe flexible PCB 2900. In the illustrative example, relief cuts, such asthe cut-out 1110 may be formed as a rounded elongated rectangular cutoutand the cut-out 2920, may be formed in a “dog bone” shape (e.g., twosubstantially circular sections connected by a rectangular section). Asmentioned, the elongated rounded rectangular cut-outs (e.g., cut-out1110) parallel to the bend line 1105 may reduce stress on the plasticsubstrate when forming the about 180-degree bend. Additionally, the dogbone-shaped cut-outs (e.g., cut-out 2920) may reduce stresses placed onthe flexible PCB substrate during use, such as by reducing stressesalong a line of deformation between battery cells. By reducing thebending stress at locations along the bend line, a probability of acatastrophic failure of the substrate (e.g., cracking, delamination, andthe like) is reduced. While cut-out 1110 is shown as a roundedrectangular shape and the cut-out 2920 is shown as a dog bone shape,other shapes may be used to reduce stress due to bending and/or flexingof the flexible PCB 2900. While a dog bone shape is shown on theillustrative example, other cut shapes may be used to achieve a same orsimilar purpose. Such other shapes may include circular cuts which maybe used, for example, for removing more weight, ovular cuts which mayprovide additional stress relief, for example, based on the curves,elongated slots, which, for example, may be similar to the rectangularcuts but with even more filet on corners to reduce additional stresses,or the like.

The flexible PCB 2900 may also include a plurality of solder pads (e.g.,pads 1150) to provide electrical connection for the cathode and anode ofeach battery module. For battery cells located near an edge of theflexible PCB 2900, the cathode an anode connectors may be bent over theedge of the flexible PCB 2900. For battery cells located away from theedge of the flexible PCB, a plurality of cut-outs (e.g., cut-out 1140)are located near a corresponding pad 1150 to allow for solder or weldconnection of the battery cathode or anode connector to the flexible PCB2900. Additionally, the flexible PCB 2900 may include chargingconnection portion 1180 that may be used to connect to one or morecharging tabs on an exterior portion of a case of the conformal wearablebattery enclosure and/or a flexible connector portion 1160 that mayinclude one or more flexible connectors to connect to additionalcircuitry, such as a control module, a display module, or the like). Theflexible PCB 2900 may also include one or more semi-circular cut-outsections to provide an area of low mechanical stress at an interiorportion of the flexible PCB 2900. In some cases, an electrical component1280, shown in FIG. 30, (e.g., a thermistor) may be physically connectedto the flexible PCB 2900 in this area such that the electrical componentdoes not receive stress loads while the CWB is flexed during use. Suchstress loads, without the stress relief provided by the semi-circularcut-outs, may cause the electrical component to detach from the flexiblePCB 2900.

FIG. 47B shows second view of the illustrative flexible printed circuitboard 2900 for the illustrative conformal wearable battery systemaccording to aspects of the present disclosure. In some cases,connection locations for each battery cell may be marked and/or mayinclude a rigidizing material, or may be otherwise reinforced. Eachbattery cell location 1230 may be associated with a pair of cut-outs forthe anode and cathode connections, as discussed above. Here, a batterycell module may be physically attached to the substrate of the flexiblePCB 2900, such as by use of an adhesive material (e.g., glue, tape,etc.). The cathode and anode connection tabs may be inserted through acorresponding cut-out 1140 so that the connection tabs may be soldered,welded, or otherwise connected to the connection pad 1150 on the otherside of the flexible PCB 2900.

The electrical connection cut-outs (e.g., cut-out 1140) may be disposednear a flex line 1250 between rows of battery cell locations 1230 at adistance configured to reduce or eliminate stresses applied to the celltabs (e.g., a cathode connection tab, an anode connection tab) of eachbattery cell. Because the battery cell locations are reinforced orotherwise stiffened by the battery modules, the flex lines 1250 allowfor the CWB to be flexed within a designed range of motion, when in use.To provide stress relief along these flex lines between the rigidbattery cell portions, the dog bone-shaped cut-outs 2920 are disposedwithin each flex line 1250 and may be aligned with a portion of thebattery cell connection cut-outs (e.g., cut-out 1140).

FIG. 47C shows a partial second view of the illustrative flexibleprinted circuit board 2900 including cut-outs providing strain reliefalong a center line according to aspects of the present disclosure. Asdiscussed above, the rectangular cut-out 1110 may be disposed centeredon and parallel to the bend line 1105 at the center of the flexible PCB2900, where at least a portion of the cut-out 1110 may be disposedunderneath a battery cell module when installed. In an illustrativeexample, a battery cell connection area 1330 may be about 50 mm inlength, where the cut-out 1110 may be located near a mid-point of thebattery cell connection area 1330. In an illustrative example, a firstedge 1312 a of the cut-out 1110 may be located at a first distance(e.g., about 11.5 mm) from a first edge of the battery cell connectionarea 1330, the second edge 1312 b of the cut-out 1110 may be located ata second distance (e.g., about 11.5 mm) from the second edge of thebattery cell connection area 1330, and the length of the cut-out 1110between the first edge 1312 a and the second edge 1312 b may be a firstdimension (e.g., about 25 mm). In some cases, locations and/or sizes ofcut-outs may differ between locations on the flexible PCB. A width ofthe cut-out between the left edge 1314 a and the right edge 1314 b maybe a second dimension (e.g., about 4.5 mm), and a radius of each roundedcorner 1316 may be a third dimension (e.g., about 1.1 mm). The specificdistances and/or dimension are given for illustrative purposes and otherdistances and/or dimensions may be contemplated within the scope of thisdisclosure.

The illustrative dog bone-shaped cut-out 2920 may be formed as arectangular area 2322 b connecting two circular areas 2328 a and 2328 b.For example, the dog bone-shaped connector 2920 may be centered on andperpendicular to the bend line 1105. The rectangular area 2322 b may beabout 1 mm high and about 2.25 mm wide. Each circular area 2328 a and2328 b may have a radius of about 2 mm.

The illustrative battery connection cut-out 1140 may be formed as anelongated oval shape of about 1.5 mm high and having a distance of about6 mm between a center point of each circular end portion (e.g., 1344)and an overall length of about 9 mm. In some cases, a second edge 1342 bof the cut-out 1140 may align with a center line through the dogbone-shaped cut-out 2920. Additionally, the dog bone-shaped cut-out 2920may be located about 4.8 mm from the battery connection cut-out 1140.

FIG. 47D shows a first view of the illustrative flexible printed circuitboard 2900 folded along the bend line 1105 according to aspects of thepresent disclosure. For example, a 180-degree bend 1405 may be formedalong the bend line 1105, such as when a left half of the flexibleprinted circuit board 2900 is folded over a right half of the flexibleprinted circuit board 2900 such that the battery modules are located onthe exterior portion of the folded flexible printed circuit board 2900and the electrical connections for the battery modules are disposed onan interior portion of the folded flexible printed circuit board 2900.

While aspects of the disclosure have been described with reference tobattery cells and/or a CWB comprising battery cells, arrangements andmethods as described herein may also be applied to other devices andsystems having a flexible PCBA to maximize space within a housing. Forexample, the arrangements and methods described herein may apply to anyelectronic device disposed within a housing for which maximizing usableinterior space within a housing by folding a flexible PCBA within theavailable interior space is desired. Examples of such electronic devicesmay include underwater cameras, sonar devices, radar devices, lidardevices, emergency radio beacons, satellite communications devices,terrestrial wireless communications devices, global positioning system(GPS) receivers, electronic environmental sensor devices, electronicmedical devices, computing processors, solar cell based power generationdevices, wave motion based power generation devices, fuel cell basedpower generation devices, battery charging controllers, and/or portablechemical batteries for powering electronic or electrical devices.

In an illustrative example, a conformal wearable battery may include aplurality of battery cells and a flexible printed circuit board assembly(PCBA). The flexible PCBA may include a plurality of physical connectionsections disposed in a grid like pattern, wherein each of the pluralityof battery cells is physically affixed to the flexible PCBA at acorresponding physical connection section of the plurality of physicalconnection sections, a bend axis disposed between two parallel physicalconnection sections, wherein the bend axis facilitates folding of theflexible PCBA in half. Additionally, the flexible PCBA may include aplurality of first cut-outs disposed along the bend axis, wherein eachfirst cut-out of the plurality of first cut-outs is disposed parallel tothe bend axis and a plurality of second cut-outs disposed across thebend axis, wherein each second cut-out of the plurality of secondcut-outs are disposed perpendicular to the bend axis.

The conformal wearable battery of the illustrative example may include afirst plurality of electrical connections each connecting a cathode of acorresponding battery cell of the plurality of battery cells and secondplurality of electrical connections each connecting an anode of thecorresponding battery cell of the plurality of battery cells toelectrical conductors of the flexible printed circuit board assembly.

The conformal wearable battery of the illustrative example, may includea bend axis where the bend axis comprises a center portion of the gridlike pattern of the physical connection sections.

The conformal wearable battery of the illustrative example, may includethe plurality of cut-outs where each first cut-out of the plurality offirst cut-outs is rectangular-shaped, and where a longer edge of eachfirst cut-out is disposed parallel to the bend axis.

The conformal wearable battery of the illustrative example, where eachcorner of each first cut-out of the plurality of first cut-outs isrounded.

The conformal wearable battery of the illustrative example, where eachsecond cut-out of the plurality of second cut-outs comprises a firstsemi-circular section, a second semi-circular section and a rectangularsection.

The conformal wearable battery of the illustrative example, where therectangular section is disposed between the first semi-circular sectionand the second semi-circular section.

The conformal wearable battery of the illustrative example, where therectangular section is disposed laterally across the bend axis, whereina mid-point of the rectangular section is located near the bend axis.

The conformal wearable battery of the illustrative example, where eachof the plurality of battery cells is physically attached to a first sideof the flexible PCBA.

The conformal wearable battery of the illustrative example, where theplurality of battery cells is disposed on an outside surface of theflexible PCBA, when the flexible PCBA is in a folded configuration.

The conformal wearable battery of the illustrative example may furtherinclude a sealed flexible housing wherein the flexible PCBA is disposedwithin an interior cavity of the sealed flexible housing and wherein theflexible PCBA is in a folded configuration.

A second illustrative example of a system may include a plurality ofbattery cell modules and a flexible printed circuit board assembly(PCBA). The flexible PCBA includes a plurality of battery cellconnection sections disposed in a grid-like pattern along a firstsurface of the flexible PCBA, a bend axis configured to divide theflexible PCBA in half when the flexible PCBA is in a foldedconfiguration, and a plurality of cut-outs disposed along the bend axis,wherein each of the plurality of cut-outs reduce a bending force placedon the flexible PCBA when a flexing force is applied to the flexiblePCBA.

The system of the second illustrative example, where the plurality ofcut-outs comprises a plurality of first cut-outs having a first shape,and a second plurality of cut-outs having a second shape.

The system of the second illustrative example, where the first shapecomprises a substantially rectangular shape having rounded corners.

The system of the second illustrative example, where the second shapecomprises at least one semi-circular section and a rectangular section.

The system of the second illustrative example, where the second shapecomprises a rectangular section disposed across the bend axis and afirst semi-circular section disposed at an end of the rectangularsection on a first side of the bend axis and a second semi-circularsection disposed at an opposite end of the rectangular section and on anopposite side of the bend axis.

The system of the second illustrative example, where a first pluralityof cut-outs of the plurality of cut-outs are located near an approximatemid-point of a battery cell module.

The system of the second illustrative example, where a portion of theplurality of cut-outs is disposed on a bend line that is perpendicularto the bend axis and between two adjacent battery cell modules

A third illustrative example may include a flexible printed circuitboard assembly (PCBA) comprising a plurality of battery modulesphysically affixed to the flexible PCBA, wherein the plurality ofbattery modules are arranged in a grid-like pattern, a bend axis near anapproximate mid-point of the flexible PCBA, wherein bending the flexiblePCBA along the bend axis folds the flexible PCBA in half, and aplurality of cut-outs disposed along the bend axis, wherein the cutoutsreduce a force exerted on the flexible PCBA along the bend axis when theflexible circuit board is flexed.

The flexible PCBA of the third illustrative example, where the pluralityof cut-outs disposed along the bend axis comprise a plurality of firstcut-outs having a first shape and a plurality of second cut-outs havinga second shape and wherein the plurality of first cut-outs are disposedalong a flexible portion of the flexible PCBA between adjacent rows ofthe grid-like pattern that are perpendicular to the bend axis and theplurality of second cut-outs are disposed between adjacent batterymodules in columns of the grid-like pattern, wherein the columns are onopposite sides of the bend axis.

Aspects of the disclosure have been described in terms of illustrativeexamples thereof.

Numerous other examples, modifications, and variations within the scopeand spirit of the appended claims will occur to persons of ordinaryskill in the art from a review of this disclosure. For example, one ormore of the steps depicted in the illustrative figures may be performedin other than the recited order, and one or more depicted steps may beoptional in accordance with aspects of the disclosure.

In the following description of various illustrative arrangements,reference is made to the accompanying drawings, which form a parthereof, and in which is shown, by way of illustration, variousarrangements in which aspects of the disclosure may be practiced. It isto be understood that other arrangements may be utilized, and structuraland functional modifications may be made, without departing from thescope of the present disclosure. It is noted that the accompanyingdrawings may not be drawn to scale.

It is noted that various connections between elements are discussed inthe following description. It is noted that these connections aregeneral and, unless specified otherwise, may be direct or indirect, andthat the specification is not intended to be limiting in this respect.

A rechargeable conformal wearable battery (CWB) may be worn by a user topower electronic devices that the user carries. The CWB may be subjectedto a multitude of environmental conditions such as harsh shock andvibration, moisture exposure, and extreme temperatures. The CWB may havea housing that is sealed to facilitate longer battery life and utilityfor the user regardless of environmental conditions it may encounter. Toprovide a desired power output, the CWB may include a plurality ofbattery cells, each with a rated power capacity and when electricallyconnected, may allow the CWB to provide a desired power output.

A CWB may include an array of a first quantity of battery cells disposedadjacent to one another in a horizontal direction and a second quantityof battery cells disposed adjacent to one another in a verticaldirection. The array of battery cells may be arranged in a grid-likepattern. Each of the battery cells may be encased or housed in a batterycell housing (e.g., a pouch, a metal enclosure, etc.) separate fromother battery cells. A battery cell as described herein may include aplurality of individual battery cell elements that are electricallyconnected together to form a compound battery cell that electricallyperforms as a single unit. Each of the battery cells may be physicallyconnected to adjacent battery cells by flexible elements (e.g., aflexible printed circuit board), thereby facilitating a surface outlineor shape of the array of battery cells to generally conform to a surfaceoutline or shape of a user wearing the CWB. For example, the CWB mayinclude one or more flex lines along which the CWB may flexibly conformto a shape of an object adjacent to the CWB, such as a portion of auser's body. One or more of the battery cells may include apositive-charge electrical terminal and a negative-charge electricalterminal that are electrically connected with the battery cell within aninterior of the battery cell and provide electrical power to electricaldevices disposed exterior to the battery cell. Electrical terminals of aplurality of the battery cells in the array of battery cells may beconnected together to route electrical current through the plurality ofthe battery cells and a set of positive-charge and negative-chargeelectrical terminals that are shared among the plurality of the batterycells. The positive-charge electrical terminal and the negative-chargeelectrical terminal may provide an electrical current that passesthrough an electrically conductive path, for example, through anelectronic device, via transfer of electrons through the electricallyconductive path between the positive-charge electrical terminal and thenegative-charge electrical terminal on the exterior of the battery cell.The CWB may include a set of positive-charge and negative-chargeelectrical terminals that are shared among the plurality of the batterycells of the array of battery cells. The plurality of the battery cellsmay be electrically coupled together, for example, in series or inparallel.

In some cases, each battery cell may be formed of electrodes and a solidelectrolyte that are stacked in layers or laminations and enclosed in afoil envelope housing, which is then sealed. The positive-chargeterminal and the negative-charge terminal may each include a conductiveregion that passes between the interior of the cell housing and theexterior of the cell housing.

The CWB housing may secure a plurality of the battery cells within aninterior region may be formed from a molding process such as injectionmolding. The CWB housing may be formed of a polymeric material, forexample. The CWB housing may be sealed to prevent ingress of solidmaterial and/or liquid material, for example, according to an IP67rating, IP68 rating, or other ingress protection rating. The CWB housingmay include a plurality of electrically conductive contacts and/orconnectors that may pass between the interior region of the CWB housingand the exterior of the CWB housing. The IP67 rating is specified by theIngress Protection Code (IP Code) IEC standard 60529. The equivalentEuropean standard is EN 60529. The IP Code also may be referred to asthe International Protection Code. The IP Code classifies and rates adegree of ingress protection provided by mechanical casings andelectrical enclosures for electronic equipment against intrusion, dust,accidental contact, and liquid (e.g., water). In the IP67 rating, thefirst digit (i.e., ‘6’) specifies a level of protection offered againstingress of solid objects, while the second digit (i.e., ‘7’) specifies alevel of protection offered against ingress of liquids. The larger thevalue of the digit specifying the level of protection, the greater theamount of protection offered. For example, an IP67 rating specifiestotal protection against dust ingress and protection against shortperiods of immersion in water. An IP68 rating specifies dust resistanceand immersion in 1.5 meters of freshwater for up to 30 minutes duration.

FIGS. 48 and 49 illustrate an exemplary battery cell assembly orflexible printed circuit board assembly (PCBA) 3100 of an exemplary CWB3010. In some examples, the CWB 3010 may be provided in a form factoreasily carried by a person, such as within a pocket or other means ofsecuring the CWB 3010 to a person's clothing, uniform, or the like. Asshown in FIGS. 48 and 49, the battery cell assembly or PCBA 3100 mayinclude a flexible printed circuit board (PCB) 3110 with a plurality ofbattery cells 3130 connected both electrically and physically to the PCB3110. To provide the specified power output, while also providingflexibility for conforming to a shape of person's body or equipment whencarried, a matrix of battery cells 3130 may be arranged on, and affixedto, a flexible printed circuit board 3110. To fit within the housing3160 of the CWB 3010, the flexible printed circuit board 3110 may have abend axis 3112 (e.g. a centerline) that facilitates folding of theflexible PCB 3110 to form a upper portion 3114 of the flexible PCB 3110and a lower portion 3116 of the flexible PCB 3110. Each portion 3114,3116 may be substantially the same size (i.e., same surface area). Thebattery cell 3130 may be mounted on an outward facing surface 3118A,3118B of each respective portion 3114, 3116 of the flexible printedcircuit board 3110 while the electrical connections may be made on aninward facing surface 3120A, 3120B of the respective upper and lowerportions 3114, 3116 of the folded PCB 3110. A central shock-attenuatingor shock-absorbing member 3140 may be positioned between the upperportion 3114 and the lower portion 3116 to prevent the upper portion3114 from contacting the lower portion 3116. The centralshock-attenuating member 3140 may absorb or dampen any shock and/orvibrational loading the CWB 3010 may receive while also providingelectrical insulation for the electrical contacts.

As shown in FIGS. 50A-50B, the battery cell assembly 3100 may bereceived into an interior cavity 3166 of a housing 3160 to provideprotection for the CWB 3010. The housing 3160 may include an upperhousing member 3162 and a lower housing member 3164 that may beconnected together to form the interior cavity 3166. In addition, theupper housing member 3162 and lower housing member 3164 may be sealedtogether along the perimeter to protect the battery cell assembly 3100to prevent ingress of solid material and/or liquid material. A damagedbattery cell 3130 may be a fire hazard and/or could render the CWB 3010inoperable. Accordingly, CWB 3010 may meet the requirements ofMIL-PRF-32383/4A. Each housing member 3162, 3164 may be flexible and maybe formed from a polymeric material using an injection molding or othertechnique known to one skilled in the art. Accordingly, housing 3160(and each housing member 3162, 3164) may be flexible or bendable to beable to withstand repeated bending or flexing cycles to allow CWB 3010to meet the requirements of MIL-PRF-32383/4A. The CWB 3010 may berequired to flex at least 800 times under load to a 7-inch radius curvedsurface, such that an edge of the CWB 3010 may be capable of deflecting,in each direction, at least a specified distance (i.e., 1 inch) from acenterline of the CWB 3010 without sustaining physical or electricaldamage. MIL-PRF-32383/4A is incorporated by reference in its entirety.The housing members 3162, 3164 may be injection molded from a polymericmaterial that has elastomeric properties to allow the housing members3162, 3164 and housing 3160 to flex and bend. For example, the housingmembers 3162, 3164 may be formed from a thermoplastic elastomer (TPE), athermoplastic urethane (TPU), thermoplastic vulcanizates (TPV), or othersimilar material.

The arrangement of the battery cells 3130 on the outward facing surfaces3118A, 3118B of the flexible PCB 3110 positions an outward facingsurface 3132 of each battery cell 3130 to face an interior surface 3168of the upper housing member 3162 or an interior surface 3170 of thelower housing member 3164 as shown in FIG. 51. Additionally, a pluralityof battery cell shock-attenuating members 3180 may be individuallyattached to the outward facing surface 3132 of each battery cell 3130.Similar to the central shock-attenuating member 3140, each battery cellshock-attenuating member 3180 may be electrically insulating. Eachbattery cell shock-attenuating member 3180 may be positioned between theoutward facing surface 3132 and one of the interior surfaces 3168, 3170.In addition, each battery cell shock-attenuating member 3180 may alsocontact one of the interior surfaces 3168, 3170 of the housing members3162, 3164. The central shock-attenuating member 3140 may be locatedbetween the battery cells 3130 arranged on the upper and lower portions3114, 3116 of PCB 3110, where shock-attenuating member 3140 may be incontact with both inward facing surfaces of the upper portion 3114 andthe lower portion 3116 of the flexible PCB 3110. The battery cellshock-attenuating members 3180 may located between the battery cells3130 and the housing 3160. The central shock-attenuating member 3140and/or the battery cell shock-attenuating members 3180 may help toprotect the battery cells 3130 by absorbing the forces received by theCWB 3010 from any impacts or collisions. As shown in FIG. 51, thisarrangement of having three distinct shock-attenuating members 3140,3180 spaced apart from each other through a cross-section of the CWB3010 to provide protection from impacts for the battery cells 3130throughout the CWB 3010. Each shock-absorbing member 3140, 3180 maycompress up to 80 percent when subjected to an impact load. Forinstance, each shock-absorbing member 3140, 3180, when compressed 80percent, may absorb up to 400 N of force over an area of 1140 mm² area,or 0.35 N/mm² (0.35 MPa). In addition, at higher strain rates, such asimpact or shock loading, each shock-absorbing member 3140, 3180 may becompressed up to 80 percent of the thickness, where the member 3140,3180 may push back against the impact with a pressure of less than or upto 0.40 N/mm² (0.40 MPa). In some cases, the shock-attenuating members3140, 3180 may absorb up to 30 percent and in some cases up to 50percent of an impact force applied to the CWB 3010 to protect thebattery cells 3130 from the impact force.

The battery cells 3130 may be a pouch cell type battery (i.e., apackaged polymer lithium-ion battery or similar type battery). Forinstance, each battery cell 3130 may include a pouch cell portion 3134and a foil portion 3136 that wraps around at least three sides of thepouch cell portion 3134. The foil portion 3136 may have a length that isgreater than a length of the pouch battery portion. In addition, thefoil portion 3136 may contact the sides of the pouch cell portion 3134across the width of the battery cell 3130 and/or may be integrated intoa pouch cell package. Each battery cell 3130 may have a non-cylindricalshape and may have generally rectangular cuboid shape or a substantiallyparallelepiped shape. Further, a chemical system of battery cell 3130may include one of a lithium cobalt oxide, nickel cobalt manganese,nickel cobalt aluminum, or other such chemical systems. In anillustrative example, the dimensions of the battery cell 3130 may beabout 43 mm in length, about 34 mm in width, and about 6 mm in height,but battery cells of other dimensions may be used within the scope ofthis disclosure. Additionally, the battery cell 3130 may weigh between22.5 grams and 24.5 grams (i.e., 23.5 grams) and may have an energystorage capacity between 1400 mAh and 1500 mAh (i.e., about 1,435 mAh).The size, weight, and energy storage capacity of each battery cell 3130of the CWB 3010 may be designed such that the overall size, weight, andenergy storage capacity of the flexible PCBA 3100 for the CWB 3010 meetsan energy storage capacity specification, weight specification, and/orsize specification for a CWB 3010. For example, the height, width, andlength of each battery cell 3130 may be designed, at least in part, tomeet a flexibility requirement of the CWB 3010. Additionally, the size,and/or shape of the battery cells may allow for a specified number ofbattery cells (e.g., about 36 battery cells) and/or configuration of thebattery grid such that the energy capacity for the CWB 3010 may be atleast 148 Watt-hours (Wb) (e.g., about 150 Wh, about 170 Wh, about 190Wh, about 200 Wh, etc.) and/or where the maximum weight of the CWB 3010is less than a specified maximum weight (e.g., about 2.6 pounds). Insome cases, a configuration of the battery cells 3130 of the CWB 3010may allow the CWB 3010 to output a voltage between about 10 and about 20V, (e.g., about 14.8V) within a specified size and/or shape of the CWB.For example, an illustrative CWB 3010 may have an overall dimensions ofbetween about 8.5 in. and 9.0 inches (i.e., about 8.7 in.) x betweenabout 7.5 in and 8 in. (i.e., about 7.66 in.) x between about 0.5 in.and 0.8 in. (i.e., 0.70 in.).

As the battery cells 3130 go through cycles of discharging andrecharging, the chemical reaction inside the battery cells 3130 maycause the battery cells 3130 to swell or increase in volume. In someexamples, the battery cells 3130 may also go through cycles of swellingand then shrinking (i.e., increasing and decreasing in volume) as itgoes through the discharging and recharging cycles. When a battery cell3130 swells, the cell 3130 may expand into a cavity or void 3178 createdby an opening 3188 in the battery cell shock-attenuating member 3180. Insome cases, the battery cells 3130 may encounter swelling of less than 4percent. In other cases, the battery cells 3130 may swell in a rangebetween 4 percent and 10 percent. In still other cases, the batterycells 3130 may encounter swelling of about 15 percent or less. Inaddition, each battery cells 3130 may swell different amounts in variouslocations of the battery cell 3130. For instance, each battery cell 3130may experience a greater amount of swelling in a central region thanalong its edges.

The flexible PCB 3110 for the conformal wearable battery 3010 accordingto aspects of the present disclosure. The flexible PCB 3110 may beconfigured to provide power and/or electrical signals from a pluralityof battery cells and/or other components of a CWB. The flexible PCB 3110may be formed of one or more of a flexible polymer or plastic material,such as a polyimide or other such flexible substrate. In some cases,markings showing locations of placement of battery cells may be formedthrough a silk screening process or other like method. Electricalconductors may be included in one or more layers of the flexible PCB3110. In some cases, electrical conductors may be configured as aconductive pattern (e.g., a copper overlay, a conductive ink, etc.) onthe surface of the substrate of the flexible PCB 3110. In some cases,exposed conductive features (e.g., conductors, a bare copper surface, abare aluminum surface, etc.) may be coated with a coverlay substance,such as an electrical insulator. For conductive portions of the flexiblePCB not covered with a coverlay, the surface may be plated, such as withan electroless nickel immersion gold (ENIG) finish, a lead-freeimmersion silver finish or other substances with improved conductiveproperties. The flexible PCB 3110 may have a plurality of physicalconnection sections disposed in a grid like pattern, where each of theplurality of battery cells 3130 is physically affixed to the flexiblePCB 3110 at a corresponding physical connection section of the pluralityof physical connection sections.

The central shock-attenuating member 3140 may be positioned between theupper and lower portions 3114, 3116 and may also contact the inwardfacing surfaces 3120A, 3120B of the PCB 3110. The centralshock-attenuating member 3140 may compress to absorb any impacts orforces that are received by the CWB 3010. As shown in FIGS. 52 and 53,the central shock-attenuating member 3140 may be a continuous layer freeof openings or holes that extend through the central shock-attenuatingmember 3140 in the region that corresponds to the PCB 3110. The centralshock-attenuating member 3140 may also serve to electrically insulatethe upper and lower portions 3114, 3116 from each other. The centralshock-attenuating member 3140 may have a front surface 3142, a rearsurface 3144 opposite the front surface 3142, and a perimeter surface3146 extending between the front surface 3142 and the rear surface 3144.The central shock-attenuating member 3140 may have a geometric shapethat generally follows the overall footprint or outline of the pluralityof battery cells 3130 arranged on the upper portion 3114 of the PCB3110. The central shock-attenuating member 3140 may have a rectangularshaped cutout 3148 at one corner to accommodate stiffeners 3122 arrangedon the inward facing surface 3120A of upper portion3 114 of PCB 3110.The stiffeners 3122 may help to stabilize the region of the flexible PCB3110 where the CWB control circuitry 3124 is mounted.

FIG. 52 illustrates the battery assembly 3100 with the lower portion3116 of PCB 3110 along with its attached battery cells 3130 removed forclarity. FIG. 53 illustrates a front perspective view of an illustrativecentral shock-attenuating member of the battery cell assembly of FIG. 48and FIG. 54 illustrates a front view of a portion of the battery cellassembly of FIG. 48. FIG. 55 illustrates a front perspective view of anexemplary battery cell shock-attenuating member of the battery cellassembly of FIG. 48. As shown in FIG. 52, the central shock-attenuatingmember 3140 may have a length, L1, and width, W1, that extendssubstantially the same length and width of one of the upper and lowerportions 3114, 3116 of the PCB 3110. For example, the centralshock-attenuating member 3140 may have a width that extends at least 90of a width of the upper portion 3114 and/or the lower portion 3116 ofPCB 3110. The central shock-attenuating member 3140 may be affixed toone or both of the inward facing surfaces 3118A or 3118B of the PCB 3110with an adhesive, such as with a glue, an epoxy, an acrylic, or a tape.In some examples, the central shock-attenuating member 3140 may be freefloating between the inward facing surface 3118A and 3118B or onlyattached along its perimeter.

Each battery cell shock-attenuating member 3180 may have an opening 3188extending through the thickness of the battery cell shock-attenuatingmember 3180. Each opening 3188 may create a cavity 3178 between therespective outward facing surface 3132 of the battery cell 3130 and oneof the interior surfaces 3168, 3170 of the housing 3160. The cavity 3178may provide room for a battery cell 3130 to expand into the cavity 3178to prevent any swelling induced stress on the battery cell 3130 as itexpands. The thickness of the battery cell shock-attenuating member 3180may be approximately 10 percent of the thickness of the battery cell3130, or may be within a range of 4 percent and 12 percent of thethickness of the battery cell 3130. In some examples, the opening 3188may not extend through the entire thickness of the battery cellshock-attenuating member 3180 creating cavity 3178 within the batterycell shock-attenuating member 3180. For example, the opening 3188 mayextend from the rear surface 3184 through at least 50 percent of thethickness, or through at least 75 percent of the thickness. In thesecases, the depth of the cavity 3178 may be within a range of 4 percentand 12 percent of the thickness of the battery cell 3130.

In some examples, the battery cell shock-attenuating members 3180 mayhave a front surface 3182, a rear surface 3184 opposite the frontsurface, a perimeter surface 3186 extending between the front surface3182 and the rear surface 3184, and an opening 3188 extending throughthe front and rear surfaces 3182, 3184. The opening 3188 may be locatedin substantially the center 3185 of the battery cell shock-attenuatingmember 3180 and may be substantially aligned with a center 3135 (i.e., ahorizontal and/or a vertical centerline) of a pouch cell portion 3134each battery cell 3130. For purposes of this disclosure, substantiallyaligned means that a first axis extending normal from a geometric centerpoint of a first component is collinear with a second axis extending inthe same direction as the first axis from a geometric center of a secondcomponent are within 2 mm of each other. In some examples, the opening3188 may be offset from a center of the pouch cell portion 3134. Theshape of the battery cell shock-attenuating member 3180 may besubstantially rectangular although it may have any geometric shape, suchas oval, circular, or other polynomial. In general, the shape of thebattery cell shock-attenuating member 3180 may correspond to the shapeof each battery cell 3130, where the length and width of the batterycell shock-attenuating member 3180 may be substantially the same orwithin 5 percent of the length and width of the length and width of eachbattery cell 3130. The perimeter edges of the battery cellshock-attenuating member 3180 may extend to and cover the perimeteredges of the corresponding battery cell 3130 that it is attached. Therear surface 3184 of each battery cell shock-attenuating member 3180 maybe affixed the outward facing surface 3132 of each respective batterycell 3130 with an adhesive, such as a glue, an epoxy, an acrylic, or atape.

As shown in the illustrated example, the opening 3188 may have an ovalshape or may have a different shape such as a rectangular shape,circular shape, or other geometric shape. In some examples, the opening3188 may have a size that has an area that is within a range of 30percent and 70 percent of an area of the front surface 3182 of theshock-absorbing member 3140, where the area of the front surface 3182 isdefined as the area of the front surface 3182 that is free of theopening 3188. While in other examples, the opening 3188 of each batterycell shock-attenuating member 3180 may have an area that is at least 70percent of the surface area of member 3140.

The central shock-attenuating member 3140 and the battery cellshock-attenuating members 3180 may be formed from a visco-elasticmaterial that can attenuate shock and vibration while also havingelectrically insulating properties. In addition, the shock-attenuatingmembers 3140, 3180 may be compressible to assist in absorbing anyswelling from the battery cells 3130. The battery cells 3130 may swellon one side or both sides (i.e. a front and rear side of the batterycell 3130). The shock-attenuating members 3140, 3180 may be verycompressible at low strain rates, such as a battery cell 3130 swelling,where each member 3140, 3180 may compress less than 50 percent of itsthickness, the shock-absorbing members 3140, 3180 may push back againstthe swelling battery with a pressure of less than or up to 0.05 N/mm2(0.05 MPa). As such, if any of the battery cells 3130 swell, a portionof the swelling may be absorbed by the compression of theshock-attenuating members 3140, 3180 to prevent any swelling inducedstress on the expanded battery cell 3130. In some examples, theshock-attenuating members 3140, 3180 may be compressed within a range of7 percent and 12 percent. The shock-attenuating members 3140, 3180 maybe resilient to resist any permanent deformation caused by any swellingof the battery cells 3130. This resilience allows for theshock-attenuating members 3140, 3180 to compress and expand toaccommodate any cycling of a battery cell 3130 swelling and thencontracting partly or completely back to its normal size. By compressingand expanding to correspond with the swelling and shrinking of thebattery cell 3130, the shock-absorbing members 3140, 3180 may notpermanently deform or may have a minimal compression set. In someexamples, the shock-attenuating members 3140, 3180 may have a maximumcompression set of between 2 percent and 5 percent when tested usingASTM D 1667-90 Test D@73° F.(23° C.).

The visco-elastic material may be formed from a polymeric material suchas a polyurethane based material such as Poron®, Sorbothane® or similarmaterial. In some cases, the visco-elastic material may absorb heat toassist in conducting heat away from the batteries. The centralshock-attenuating member 3140 and/or the battery cell shock-attenuatingmembers 3180 may be formed from the same material or, in some examples,formed from different materials. The material forming the centralshock-attenuating members and/or the battery cell shock-attenuatingmembers 3180 may be a polymeric foam (i.e., porous) or a solid polymericmaterial. The central shock-attenuating members and/or the battery cellshock-attenuating members 3180 may be formed from a sheet of materialand then cut to the final shape using a die cutting, laser cutting,water jet cutting process, or other cutting process known to one skilledin the art. The central shock-attenuating members 3140 and/or thebattery cell shock-attenuating members 3180 may have a constantthickness, where the thickness of the central shock-attenuating member3140 may substantially the same thickness (i.e., within 10 percent) as athickness of at least one of the plurality of battery cellshock-attenuating members 3180. In some examples, the thickness of thecentral shock-attenuating member 3140 may be greater than a thickness atleast one of the plurality of battery cell shock-attenuating members3180. For instance, the thickness of the central shock-attenuatingmember 3140 may be within a range of 1.2 and 1.4 times a thickness ofone of the plurality of battery cell shock-attenuating members 3180.Additionally, the thickness of the central shock-attenuating member 3140may be approximately 3 percent of the overall thickness of the CWB 3010,where the thickness of the housing 3160 is defined as the distance, T1,from an outermost outward facing surface 3174 of the upper housingmember 3162 to an outermost outward facing surface 3176 of the lowerhousing member 3164. In some examples, the thickness of the centralshock-attenuating member 3140 may be within a range of 2 percent and 5percent of the thickness, T1, of the housing 3160. In addition, thecombined thicknesses of the shock-absorbing members 3140, 3180 may beapproximately 9 percent of the overall thickness T1 of the CWB 3010, orwithin a range of 7 percent and 11 percent of the overall thickness, T1.

Aspects of the disclosure have been described in terms of illustrativeexamples thereof. Numerous other examples, modifications, and variationswithin the scope and spirit of the appended claims will occur to personsof ordinary skill in the art from a review of this disclosure. Forexample, one or more of the steps depicted in the illustrative figuresmay be performed in other than the recited order, and one or moredepicted steps may be optional in accordance with aspects of thedisclosure.

A rechargeable conformable wearable battery (CWB) assembly may be wornby a user to power electronic devices that the user carries. The CWBassembly may be subjected to environmental conditions that the user isalso subjected to. The CWB may be subjected to a multitude ofenvironmental conditions such as harsh shock and vibration, moistureexposure, and extreme temperatures. The CWB may have a sealed housingthat is sealed to facilitate longer battery life and utility for theuser regardless of environmental conditions that the CWB may encounter.To provide a desired power output, the CWB may include a plurality ofbattery cells, each with a rated power capacity and when electricallyconnected, may allow the CWB to provide a desired power output andwithin a specified size range and/or weight range.

A CWB may include an array of a first quantity of battery cells disposedadjacent to one another in a horizontal direction and a second quantityof battery cells disposed adjacent to one another in a verticaldirection. The array of battery cells may be arranged in a grid-likepattern. Each of the battery cells may be encased or housed in a batterycell housing (e.g., a pouch, a metal enclosure, etc.) separate fromother battery cells. A battery cell as described herein may include aplurality of individual battery cell elements that are electricallyconnected together to form a compound battery cell that electricallyperforms as a single unit. Each of the battery cell housings may bephysically connected to adjacent battery cell housings by flexibleelements (e.g., a flexible printed circuit board), thereby facilitatinga surface outline or shape of the array of battery cells to generallyconform to a surface outline or shape of a user wearing the CWB. Forexample, the CWB may include one or more flex lines along which the CWBmay flexibly conform to a shape of an object adjacent to the CWB, suchas a portion of a user's body. One or more of the battery cell housingsmay include a positive-charge electrical terminal and a negative-chargeelectrical terminal that are electrically connected with the batterycell within an interior of the battery cell housing and provideelectrical power to electrical devices disposed exterior to the batterycell housing. Electrical terminals of a plurality of the battery cellsin the array of battery cells may be connected together to routeelectrical current through the plurality of the battery cells and a setof positive-charge and negative-charge electrical terminals that areshared among the plurality of the battery cells. The positive-chargeelectrical terminal and the negative-charge electrical terminal mayprovide an electrical current that passes through an electricallyconductive path, for example, through an electronic device, via transferof electrons through the electrically conductive path between thepositive-charge electrical terminal and the negative-charge electricalterminal on the exterior of the battery cell housing. The CWB mayinclude a set of positive-charge and negative-charge electricalterminals that are shared among the plurality of the battery cells ofthe array of battery cells. The plurality of the battery cells may beelectrically coupled together, for example, in series or in parallel.

In some cases, the battery cell may be formed of electrodes and a solidelectrolyte that are stacked in layers or laminations and enclosed in afoil envelope housing, which is then sealed. The positive-chargeterminal and the negative-charge terminal may each include a conductiveregion that passes between the interior of the cell housing and theexterior of the cell housing at an outer wall of the casing. Theconductive region may be affixed and electrically connected to thebattery cell in an interior of the cell housing at one end, pass throughthe sealed wall of the casing, and affix to conductive elements thatelectrically couples with electrical devices at an exterior of the cellhousing.

The CWB housing may be formed of a molded casing that may be createdthrough a molding process, such as an injection molding process. Themolded CWB housing may be formed of a polymeric material, for example.The CWB housing may be sealed to prevent ingress of solid materialand/or liquid material, for example, according to an IP67 rating, IP68rating, or other ingress protection rating. In some cases, the CWBhousing may be created through connecting at least two housing portionsinto a complete sealed housing to encase the battery cells within thecasing. The positive-charge terminal and the negative-charge terminalmay each include a conductive region that passes between the interior ofthe CWB housing and the exterior of the CWB housing.

In some cases, the CWB may be provided in a form factor easily carriedby a person, such as within a pocket or with other means of securing theCWB assembly to a person's clothing, uniform, or the like. To providethe specified power output, while also providing flexibility forconforming to a shape of person's body or equipment when carried, thematrix of battery cells may be arranged on, and affixed to, a flexibleprinted circuit board.

To fit within the housing of the CWB assembly, the flexible printedcircuit board assembly may be configured to be folded along an axis(e.g., a center line), such that battery cell modules may be on anexterior surface of the flexible printed circuit board assembly closestto the housing, while the electrical connections may be made on aninterior surface of the folded printed circuit board assembly. Anelectrical insulator (e.g., foam, insulating tape, etc.) may be placedbetween the folded sections to provide electrical insulation for theelectrical contacts.

FIG. 56 shows a first view of an illustrative flexible printed circuitboard (PCB) 4100 for an illustrative CWB according to aspects of thepresent disclosure. The flexible PCB may be configured to provide powerand/or electrical signals from a plurality of battery cells and/or othercomponents of a CWB. The flexible PCB 4100 may be formed of one or morelayers of a flexible polymer or plastic material, such as a polyimide orother such flexible substrate. In some cases, markings showing locationsto facilitate placement of battery cells may be included on a surface ofthe flexible PCB 4100, such as those formed through a silk-screeningprocess, or other like method. Electrical conductors may be included inone or more layers of the flexible PCB. In some cases, electricalconductors may be configured as a conductive pattern (e.g., a copperoverlay, a conductive ink, etc.) on the surface of the substrate of theflexible PCB 4100. In some cases, exposed conductive features (e.g.,conductors, a bare copper surface, a bare aluminum surface, etc.) may becoated with a coverlay substance, such as an electrical insulator. Forconductive portions of the flexible PCB not covered with a coverlay, thesurface may be plated, such as with an electroless nickel immersion gold(ENIG) finish, a lead-free immersion silver finish or other substanceswith improved conductive properties.

The flexible PCB 4100 may be configured to bend along a bend line 4105located at or near a center line of the flexible PCB 4100 such as toform a bend of a desired angle (e.g., a 4180-degree bend). One or moreelongated cut-outs may be disposed parallel to the bend line 4105 (e.g.,cut-out 4110) and/or perpendicular to the bend line 4105 (e.g., cut-out4120), where the cut-outs perpendicular to the bend line 4105 may bealigned with a flex line (e.g., a flex line 4125 a, a flex line 4125 b,a flex line 4125 c, etc.) perpendicular to the bend line 4105. In somecases, the flex line may correspond to a section of the flexible PCB4100 located between rows of components (e.g., battery cells) alongwhich the CWB may bend during use. Such cut-outs may provide additionalflexibility to the flexible PCB 4100 to allow for easier formation ofthe desired bend angle (e.g., the 180-degree bend) such as by foldingthe right half of the flexible PCB 4100 over the left half of theflexible PCB 4100 and/or flexing along one or more adjacent flex lines.In the illustrative example, relief cuts, such as the cut-out 4110 maybe formed as a rounded elongated rectangular cutout and the cut-out4120, may be formed in a generally obround shape (e.g., twosubstantially semi-circular sections connected by a rectangularsection). As mentioned, the elongated rounded rectangular cut-outs(e.g., cut-out 4110) parallel to the bend line 4105 may reduce stress onthe plastic substrate when forming the about 180-degree bend.Additionally, the obround-shaped cut-outs (e.g., cut-out 4120) mayreduce stresses placed on the flexible PCB substrate during use, such asby reducing stresses along a line of deformation (e.g., the flex line4125 a, a flex line 4225 a of FIG. 57, etc.) between battery cells.

In some cases, additional cut-outs may be included to reduce stressesalong the flex line (e.g., the flex line 4125 a, the flex line 4125 b,the flex line 4125 c), such as at an edge of the flexible PCB 4100, suchas a corner notch 4190 a located near a corner formed in the edge of theflexible PCB 4100 near a flex line and/or a notch 4190 b located alongan edge of the flexible PCB 4100 and aligned near a flex line. Byreducing the bending stress at locations along the bend line, aprobability of a catastrophic failure of the substrate (e.g., cracking,delamination, and the like) is reduced. While cut-out 4110 is shown as arounded rectangular shape and the cut-out 4120 is shown as an obroundshape, other shapes may be used to remove weight and/or to reduce stressdue to bending and/or flexing of the flexible PCB 4100. While an obroundshape is shown on the illustrative example, other cut shapes may beused. Such other shapes may include circular cuts which may be used, forexample, for removing more weight, oval cuts which may provideadditional stress relief, for example, based on the curves, elongatedslots which, for example, may be similar to the rectangular cuts butwith even more filet on corners that may reduce additional stresses, adog-bone shape (e.g., two substantially circular sections connected by arectangular section), and/or the like.

The flexible PCB 4100 may also include a plurality of conductive pads(e.g., pads 4150) to provide electrical connection for the cathode andanode of each battery module connected to the flexible PCB 4100. Forbattery cells located near an edge of the flexible PCB 4100, the cathodean anode connectors may be bent over the edge of the flexible PCB 4100.For battery cells located away from the edge of the flexible PCB, aplurality of cut-outs (e.g., the cut-out 4140) are located near acorresponding pad 4150 to allow for solder or weld connection of thebattery cathode or anode connector to the flexible PCB 4100.Additionally, the flexible PCB 4100 may include charging connectionportion 4190 that may be used to connect to one or more charging tabs onan exterior portion of a case of the conformal wearable batteryenclosure and/or a flexible connector portion 4160 that may include oneor more flexible connectors to connect to additional circuitry, such asa control module, a display module, or the like). The flexible PCB 4100may also include one or more semi-circular cut-out sections 4180 toprovide an area of low mechanical stress at an interior portion of theflexible PCB 4100. In some cases, an electrical component 4280, shown inFIG. 57, (e.g., a thermistor) may be physically connected to theflexible PCB 4100 in this area such that the electrical component doesnot receive stress loads while the CWB is flexed during use. Such stressloads, without the stress relief provided by the semi-circular cut-outs,may cause the electrical component to detach from the flexible PCB 4100.

FIG. 57 shows second view of the illustrative flexible printed circuitboard 4100 for the illustrative conformal wearable battery systemaccording to aspects of the present disclosure. In some cases, physicalconnection locations for each battery cell may be marked (e.g., batterycell location 4210, 4230, etc.). Additionally, one or more physicalconnection locations for electrical circuitry may be marked or unmarked(e.g., circuitry module location 4240, circuitry module 4250, etc.). Theflexible PCB4 100 may also include one or more cut-out areas of theflexible PCB 4100 (e.g., cut out area 4260, cut out area 4270, etc.) toaccommodate inclusion of electrical connectors (e.g., flexibleconnection portion 4160, etc.), such as those provided to provide,and/or receive, information and/or electrical power to/from one or moreexternal devices. In some cases, one or more of the battery cellconnection locations and/or the connection locations for electricalcircuitry may include a rigidizing material, or may be otherwisereinforced.

The battery cell locations, circuitry module locations, cut outs, and/orelectrical connection locations may be provided in a matrix or gridpattern on an outward facing surface or front side of the flexible PCB4100. For example, the battery cell locations may be arranged in rows,such as battery cell row 4232, battery cell row 4234, and the like,an/or in columns, such as battery cell column 4233, battery cell column4235, and the like. Additionally, one or more of the cut-out area 4260,the cut-out area 4270, the circuitry module location 4240, the circuitymodule 4250, and the like may be aligned in a same row (e.g., row 4236).In some cases, one or more of the cut-out areas, circuitry module areas,and/or electrical connection areas may be located in different rowsand/or columns of the matrix or grid pattern. In some cases, a matrix orgrid pattern may include a combination of one or more of the batterycell locations, the one or more circuitry module locations and/or thecut-out locations. In the illustrative configuration shown in FIG. 57,the matrix or grid pattern may include 36 battery cell locations, 2circuitry module locations, and two cut-out locations, where one of thecut-out locations accommodates the flexible connection portion 4160.

In some cases, each battery cell location 4230 may be associated with apair of cut-outs for the anode and cathode connections, as discussedabove. Here, a battery cell module may be physically attached to thesubstrate of the flexible PCB 1400, such as by use of an adhesivematerial (e.g., glue, tape, etc.) or other such bonding material. Thecathode and anode connection tabs may be inserted through acorresponding cut-out 4140 so that the connection tabs may be soldered,welded, or otherwise connected to the connection pad 4150 on theopposite side of the flexible PCB 4100. Additional to a plurality ofbattery cell locations (e.g., 36 battery cell locations), the flexiblePCB 4100 may include one or more locations, marked or unmarked on theflexible PCB 4100, where electronic circuit modules may be attached,such as the electronic circuit location 4240, the electronic circuitlocation 4250, and the like. For example, electronic circuit modules maybe physically attached to the substrate of the flexible PCB 4100, suchas by use of an adhesive material (e.g., glue, tape, etc.) or other suchbonding material. Further, the flexible PCB 4100 may include a cut-outsection 4260 that is of similar size to a battery cell location 4230that may also be inclusive of at least a portion of an area associatedwith one or more flex lines (e.g., a flex line 4125 a, a flex line 4225b), and the like. The cut-out section 4270 may be configured tocorrespond with the flexible connector portion 4160.

In some cases, the electrical connection cut-outs (e.g., cut-out 4140)and/or end cut outs (e.g., cut-out 4190 a, 4190 b) may be disposed nearor offset from the flex line 4125 b between rows of battery celllocations 4230 at a distance configured to reduce or eliminate stressesapplied to the cell tabs (e.g., a cathode connection tab, an anodeconnection tab) of each battery cell. Because the battery cell locationsare reinforced or otherwise stiffened by the battery modules, the flexlines 4225 a-i and 4125 a-c may allow for the CWB to be flexed within adesigned range of motion, when in use. To provide stress relief alongthese flex lines between the rigid battery cell portions, theobround-shaped cut-outs 4120 are disposed within each flex line 4125 andmay be aligned with a portion of the battery cell connection cut-outs(e.g., cut-out 4140) and the edge cut-outs 4190 a, 4190 b may be alignedto the flex lines 4125 and located at an edge of the flexible PCB 4100.

FIG. 58 shows a partial second view of the illustrative flexible printedcircuit board 4100 including markings for placement of two batterymodules, cut-outs through which battery cell tabs are placed forconnection on the opposite side, and cut-outs providing strain reliefalong a center line and/or along a flex line perpendicular to the centerline according to aspects of the present disclosure. As discussed above,the rectangular cut-out 4110 may be disposed centered on and parallel tothe bend line 4105 at the center of the flexible PCB 4100, where atleast a portion of the cut-out 4110 may be disposed underneath a batterycell module when installed. In an illustrative example, a battery cellconnection area 4330 may be about 50 mm in length along an edge 4332 andabout 35 mm in width along an edge 4334. In some cases, along the flexline 4105, the cut-out 4110 may be located near a mid-point of thebattery cell connection area 4330.

In the illustrative example of FIG. 58, a first edge 4312 a of thecut-out 4110 may be located at a first distance (e.g., about 11.5 mm)from a first edge of the battery cell connection area 4330, the secondedge 4312 b of the cut-out 4110 may be located at a second distance(e.g., about 11.5 mm) from the second edge of the battery cellconnection area 4330, and the length of the cut-out 4110 between thefirst edge 4312 a and the second edge 4312 b may be a first dimension(e.g., about 25 mm). A width of the cut-out between the left edge 4314 aand the right edge 4314 b may be a second dimension (e.g., about 4.5mm), and a radius of each rounded corner 4316 may be a third dimension(e.g., about 1.1 mm). The specific distances and/or dimension are givenfor illustrative purposes and other distances and/or dimensions may becontemplated within the scope of this disclosure.

The illustrative obround-shaped cut-out 4120 may be formed as arectangular area 4322 b connecting two semi-circular areas 4328 a and4328 b. For example, the obround-shaped connector 4120 may be centeredon and perpendicular to the bend line 4105. The rectangular area 4322 bmay larger than the distance between adjacent battery cell connectionareas. Each semi-circular area 4238 a and 4328 b may overlap at least aportion of adjacent battery connection areas.

The illustrative battery connection cut-out 4140 may be formed as anelongated oval shape, such as an illustrative shape of about 1.5 mm high(e.g., between edge 4342 a and edge 4342 b) and having a distance ofabout 6 mm between a center point of each circular end portion (e.g.,point 4344) and an overall length of about 9 mm. In some cases, the edge4342 b of the cut-out 4140 may align with a center line through theobround shaped cut-out 4120. Additionally, the obround-shaped cut-out4120 may be located a distance (e.g., about 4 mm) from the batteryconnection cut-out 4140.

Spacing of the battery cell connection areas may be configured to allowfor construction of the finished CWB and/or for a specified amount ofmovement (e.g., flexing, bending, etc.) of the CWB when in use. Forexample, the spacings of the battery cells relative to flex lines 4225a-4225 i and/or flex lines 4125 a-4125 c may allow for an amount offlexing or bending of the CWB as defined in a specification such as, forexample, MIL-PRF-32383/4A, while maintaining structural integrity. Forexample, the spacings of battery cell connection areas may allow forbending of the CWB such that a center section of the CWB to bend whilethe edges of the CWB are held stationary. In some cases, the edges ofthe CWB may pivot in the direction of the bend. Upon application offorce to the center section of the CWB, e.g., at a distance equidistantbetween centerline edges of the CWB, the center portion of the CWB mayflex up and/or down a specified distance (e.g., at least one inch,between 1 inch and two inches, etc.). For example, spacing of thebattery cell connection areas 4330 may be distributed as a grid ormatrix pattern such that spacing between allows for uniform distributionof the adjacent battery cell connection areas, along column of batterycell location areas (e.g., column 4235) and/or along rows of batterycell connection areas (e.g., row 4234). In some cases, spacing ofadjacent battery cell connection areas adjacent to a central flex line(e.g., flex line 4105) may differ such as to allow for forming a180-degree bend in the flexible PCB 4100. In the illustrative exampleshown in FIG. 58, spacing of adjacent columns of battery cell connectionareas (e.g., column 4233, column 4235) are illustrated in the spacingbetween sides 4332 a and 4332 a′ of adjacent battery cell areas and hasa distance of about 2.3 mm. As mentioned, to allow for formation of a180-degree bend in the flexible PCB 4100, spacing along a central line(e.g., flex line 4105, flex line 4225 e) may be the same as thosebetween other adjacent columns of battery cell connection areas or maybe different. In the illustrative example of FIG. 58, spacing betweenside 4332 and 4332′ may be about 2.68 mm. Spacing between adjacent rowsof battery cell connection areas may be configured to allow for flexingand/or bending of the CWB and/or to facilitate electrical connection ofa battery cell to the flexible PCB 4100. In the illustrative example ofFIG. 58, spacing of adjacent rows of battery cell location areas (therow 4232, the row 4234, the row 4236, the row 4238) are illustrated inthe spacing between sides 4334 and 4334′ of adjacent battery cell areasand has a distance of about 4.4 mm. The specific distances and/ordimension are given for illustrative purposes and other distances and/ordimensions may be contemplated within the scope of this disclosure.

FIG. 59 shows a first view of the illustrative flexible printed circuitboard 4100 folded along the bend line 4105 according to aspects of thepresent disclosure. For example, a 180-degree bend 4405 may be formedalong the bend line 4105, such as when a left half of the flexibleprinted circuit board 4100 is folded over a right half of the flexibleprinted circuit board 4100 such that the battery modules are located onthe exterior portion of the folded flexible printed circuit board 4100and the electrical connections for the battery modules are disposed onan interior portion of the folded flexible printed circuit board 4100. Adiameter of the bend 4405 corresponds the length of the rectangularportion of the obround-shaped cut-out 4120. In the illustrative example,the diameter of the bend 4405 is about 2.25 mm.

FIGS. 60A-60C show first views of a flexible printed circuit boardassembly (PCBA) 4500 before folding along the bend line 4105 accordingto aspects of the present disclosure. As shown in FIG. 60A, electricallyconductive cathode tabs and anode tabs 4540 extend from correspondingbattery cell modules through corresponding cut-outs 4140 so that eachconductive tab 4540 may be soldered, welded or otherwise connected to acorresponding electrical connection pad 4150 forming an electricalconnection for each battery cell to the flexible PCBA 4500. Theelectrical connection pads 4150 may include an electroless nickelimmersion gold (ENIG) surface coating, a lead-free immersion silversurface coating, or other coating that improves electrical connectiondurability and conductivity between the electrically conductiveconnection tabs and the electrical connection pads. The connection pad4150, and/or its surface coating, may allow for individual joining tofacilitate connection of aluminum, nickel, or copper battery tabs 4540.The electrically conductive connection tabs 4540 may be connected tocorresponding connection pads 4150 using spot welding, ultrasonicwelding, laser welding, and/or other welding or connection technique toreduce an amount of heat applied to the surface during the attachmentprocess, an amount of material needed to form the joint while alsoincreasing quality and/or a rate of production compared to typicalsoldering.

Because of the compact nature of the CWB and the folded configuration ofthe flexible PCBA 4500, the electrical connection between the connectionpads 4150 and the battery connection tabs 4540 may be minimized withrespect to the height of the overall connection relative to the inwardfacing surfaces 4520A, 4520B. For instance, by using a welding techniquethat applies localized heat over a smaller amount of time compared totraditional soldering, the amount of material, and heat, needed to forma solid connection may be reduced. This means that the outward facingsurface of the connection tab 4540 may be have little to no additionalmaterial on it after being secured to the pad 4150. Further, byminimizing applied heat during the connection process, a probabilitythat the folded flexible PCBA 4500, the battery cell(s), or othercomponent near the connection site may be damaged is similarly reduced.In some cases, the joint may be formed using only by joining thematerial of the pad 4150 and the material of the connection tab 4540without the addition of solder, weld filler, or any additional material.By minimizing the amount of material in the joint, the height, H1, ofthe connection may be controlled to reduce the overall thickness of thefolded flexible PCBA 4500. As shown in FIG. 63, the height, H1, may bedefined as the distance between an outward facing surface of eachconnection tab 4540 and the rear or inward facing surface 4520A or 4520Bof the flexible PCBA 4500. For example, the height, H1, of the joint maybe approximately 1.5 times the thickness of the connection tab 4540 ormay be within a range of 1.2 to 3 times the thickness of the connectiontab 4540.

As can be seen in FIGS. 60B and 60C, cathode tabs and anode tabs (e.g.,tab 4540, tab 4542, etc.) extend from corresponding battery cell modulesthrough a cut-out 4140 so that each tab 4540 may be soldered, welded orotherwise connected to the electrical connection pad 4150 forming anelectrical connection for each battery cell. In some cases, for batterycells located near an edge of the flexible PCBA 4500, the battery tabs(e.g., tab 4542) may be folded over an edge of the flexible PCB 4100 tobe physically and electrically connected to the electrical circuitry ofthe flexible PCBA 4500. To protect against short circuits and/or toprovide additional protection and/or structural integrity for the CWB,while maintaining flexibility of the overall assembly, an insulatingmaterial 4552, 4554 (e.g., a foam material, a polymeric material, etc.)may be placed over a first half of the flexible PCBA 4500 beforefolding. The insulating material 4552 may include an insulation cut-out4556 section, where edges of the insulation cut-out 4556 may be adjacentto a first electrical circuitry module 4550, a second electricalcircuitry module 4570, a connector section 4560, and/or an output module4580 (e.g., an OLED display, and LED display, and the like). In somecases, the insulating material 4552 may include one or more cutouts thatmay align with a cutout of the flexible PCB 4100, such as cut-out 4562,and cut-out 4564, as shown in FIG. 60C. In some regions of the flexiblePCBA 4500, each connection tab 4540 may extend through a cutout 4140 ofthe flexible PCB 4100 to attach to its corresponding connection pad4150, while in other regions connection tabs 4540 may extend from itsrespective battery cell and wrap around an upper edge of the PCB 4100before attaching to its corresponding connection pad 4540.

FIG. 61 shows a second view of the flexible printed circuit boardassembly 4500 before folding along the bend line 4105 according toaspects of the present disclosure. Here an array of battery cells 4610may be physically and electrically attached to the flexible PCBA 4500.For example, each battery cell module 4620 of the battery cell array4610 may be physically attached to a first side of the flexible PCBA4500. Electrical connections of each battery cell module 4620 may bepassed through a cut-out (e.g., the cut-out 4140 to allow for anelectrical and physical connection via a corresponding pad 4150 on anopposite side of the flexible PCBA. Each battery cell module 4620 of thearray of battery cells may be connected to an electrical circuit of theflexible PCBA comprising a plurality of conductive paths, where at leasta portion of the plurality of conductive paths provide redundantpathways for one of a conductive path electrically connecting theplurality of cathode tabs of the battery cell array 4610 or a conductivepath electrically connecting the plurality of anode tabs of the batterycell array 4610. Each battery cell of the battery cell array 4610 may becoupled together to provide electrical power to a desired electricalload that may be removable connected to the CWB. A positive terminal ortab of each battery cell may be coupled to a positive trace pad of apositive trace bus and a negative terminal or tab of each battery cellmay be coupled to a negative trace pad of a negative trace bus such thatthe plurality of battery cell modules of the battery cell array 4610 maybe electrically coupled in parallel with one another. In some cases, thepositive trace bus and the negative trace bus may each include aplurality of electrical pathways. For example, the positive trace busand the negative trace bus may each be formed as a conductive mesh. Insome cases, the conductive mesh may form a plurality of alternativeconductive paths connecting to the plurality of positive trace pads andnegative trace pads. Should a portion of the alternate conductive pathsof the conductive mesh be damaged, for example by a destructivepenetration to the CWB, a tear, a fracture, or other such damage to theflexible PCB, other alternative conductive pathways of the conductivemesh may be capable of providing electrical current around the damagedarea.

In some cases, one or more of the alternative conductive pathways may beconnected to one of a positive battery cell tab, a negative battery celltab, protection circuitry, data circuitry, clock circuitry and/or othercircuitry associated with operation and/or monitoring of the CWB.Circuitry associated with the battery cell may include battery chargingcontrol circuitry, for example. Conductive pathways may carry electricalcurrent and/or data signals between the battery cell and/or associatedcircuitry within an interior of a CWB housing and one or more contactcomponent accessible on the outside of the CWB housing.

FIG. 62 shows a partial first view of the flexible printed circuit boardassembly 4500 showing a partial arrangement of adjacent battery cellmodules (e.g., battery cell module 4620) when attached in an array ormatrix format on the flexible PCBA 4500. Each battery cell module 4620may include an attenuating member 4710 attached to a battery cell 4720such that when the battery cell module 4620 is physically attached tothe flexible PCBA 4500, a first side of the battery cell 4720 may beadhered or otherwise attached to the flexible PCBA 4500 and theattenuating member 4710 may be attached to an opposite side of thebattery cell module 4720.

As shown, the plurality of battery cell attenuating members 4710 may beindividually attached to the outward facing surface of each battery cell4720. Each battery cell attenuating member 4710 may be positionedbetween the outward facing surface of the battery cell 4720 so that atop surface of the attenuating member 4710 faces an interior surface ofthe CWB, when assembled. In addition, each battery cell attenuatingmember 4710 may also contact one of the interior surface of the CWB. Inshort, attenuating member 4710 may be located between the battery cells4720 arranged on the flexible PCBA 4500, and the battery cellattenuating members 4710 may located between the battery cells 4720 andthe housing of the CWB. The attenuating members 4710 may help to protectthe battery cells 4720 by absorbing the forces received by the CWB 3010from any impacts or collisions. The battery cell attenuating members4710 may be formed from a visco-elastic material that can attenuateshock and vibration. In some cases, the visco-elastic material mayinclude other properties including intumescent properties or other fireblocking and/or suppression characteristics. The visco-elastic materialmay be formed from a polymeric material such as a polyurethane basedmaterial such as Poron®, Sorbothane®, or similar material. In somecases, the battery cell attenuating members 4710 may be made of anelectrically insulative material.

Each battery cell attenuating member 4710 may have an opening 4730extending through the thickness of the attenuating member 4710. Eachopening 4730 may create a cavity between the respective outward facingsurface of the battery cell 4720 and one of the interior surfaces of thehousing of the CWB. As the battery cells 4720 go through cycles ofdischarging and recharging, the chemical reaction inside the batterycells 4720 may cause the battery cells 4720 to swell or increase involume. As the battery cells 4720 swell, they may expand into the cavitycreated by the opening 4730. In some cases, the battery cells 4720 mayencounter swelling of less than 4%. In some cases, the battery cells4720 may swell in a range between 4% and 10%. In some cases, the batterycells 4720 may encounter swelling of about 15% or less. The thickness ofthe battery cell attenuating member 4710 may be approximately 10 percentof the thickness of the battery cell 4720, or may be within a range of 8percent and 15 percent of the thickness of the battery cell 4720. Insome examples, the opening 4730 may not extend through the entirethickness of the attenuating member 4710 creating cavity withinattenuating member 4710. For example, the opening 4730 may extend fromthe rear surface through at least 50 percent of the thickness, orthrough at least 75 percent of the thickness. In these cases, the depthof the cavity may be within a range of 4 percent and 15 percent of thethickness of the battery cell 4130.

FIG. 63 shows a side view of the flexible PCBA 4500 before folding alongthe bend line according to aspects of the disclosure and FIG. 64 shows aside view of the flexible PCBA 4500 after folding along the center lineaccording to aspects of the disclosure. FIG. 65 shows a first view ofthe flexible printed circuit board assembly (PCBA) 5000 after foldingalong the bend line according to aspects of the disclosure. Afterfolding the flexible PCBA 5000, a side of the folded flexible PCBA 4500is shown to have a battery cell array or matrix having 19 battery cellmodules 5010 and an opening including a connector section. In thisillustrative example, the battery cell array may be arranged as a 5×4matrix of battery cells and an opening to accommodate the connectorsection. While the 5×4 matrix is shown, other arrangements and/orconfigurations of the battery cell matrix (e.g. a 5×5 matrix, a 4×4matrix, a 4×3 matrix, a 3×2 matrix, a 4×1 matrix, a 3×3 matrix, etc.)may be contemplated within scope of this disclosure. Once the flexiblePCBA 4500 is folded, battery cell modules affixed to either half of thefolded flexible PCBA 4500 are positioned opposite to a correspondingbattery cell module or a circuitry module.

FIG. 66 shows a partial side view of the flexible PCBA 4900 afterfolding along the bend line and FIG. 67 shows a partial first view ofthe flexible PCBA 4900 after folding along the bend line according toaspects of the disclosure.

FIGS. 68A-68D show different views of an illustrative battery cell 5300(e.g., a pouch cell packaged polymer lithium-ion battery), which may beincorporated into a battery cell module as discussed above. In somecases, a chemical system of battery cell 5300 may include one of alithium cobalt oxide, nickel cobalt manganese, nickel cobalt aluminum,or other such chemical systems. In an illustrative example, thedimensions of the battery cell 5130 may be about 43 mm in length, about34 mm in width, and about 6 mm in height, but battery cells of otherdimensions may be used within the scope of this disclosure.Additionally, the battery cell 5130 may weigh between 22.5 grams and24.5 grams (e.g., 23.5 grams) and may have an energy storage capacitybetween 1400 mAh and 1500 mAh (e.g., about 1,435 mAh). The size, weight,and energy storage capacity of each battery cell of the CWB may bedesigned such that the overall size, weight, and energy storage capacityof the flexible PCBA for the CWB meets an energy storage capacityspecification, weight specification, and/or size specification for aCWB. For example, the height, width, and length of each battery cell maybe designed, at least in part, to meet a flexibility requirement of theCWB, such that an assembled CWB may conform, under load, to a 7-inchradius curved surface, such that an edge of the CWB may be capable ofdeflecting, in each direction, at least a specified distance (e.g., 1inch) from a centerline of the CWB. Additionally, the size, and/or shapeof the battery cells may allow for a specified number of battery cells(e.g., about 36 battery cells) and/or configuration of the battery gridsuch that the energy capacity for the CWB may be at least 148 Watt-hours(Wb) (e.g., about 150 Wh, about 170 Wh, about 190 Wh, about 200 Wh,etc.) and/or where the maximum weight of the CWB is less than aspecified maximum weight (e.g., about 2.6 pounds). In some cases, aconfiguration of the battery cells of the CWB may allow the CWB tooutput a voltage between about 10 and about 20 V, (e.g., about 14.8V)within a specified size and/or shape of the CWB. For example, anillustrative CWB may have an overall dimensions of between about 8.5 in.and 9.0 inches (e.g., about 8.7 in.)×between about 7.5 in and 8 in.(e.g., about 7.66 in.)×between about 0.5 in. and 0.8 in. (e.g., 0.70in.).

FIGS. 68A-68D show different views of an illustrative battery cell 5300(e.g., a pouch cell packaged polymer lithium-ion battery), which may beincorporated into a battery cell module 5010 as discussed above. In somecases, a chemical system of battery cell 5300 may include one of alithium cobalt oxide, nickel cobalt manganese, nickel cobalt aluminum,or other such chemical systems. In an illustrative example, thedimensions of the battery cell 5300 may be in a range between about 42mm to about 44 mm (e.g., 43 mm) in length, a range between about 33 mmand 35 mm (e.g., about 34 mm) in width, and in a range between about 5mm and 7 mm (e.g., about 6 mm) in height, but battery cells of otherdimensions may be used within the scope of this disclosure. FIG. 68Dshows an illustrative side view of the battery cell 5300. Whilelithium-ion battery cells in a pouch-cell format are discussed, otherbattery formats or chemistries may be used, such as prismatic batterycells, can-type battery cells, and the like.

In FIGS. 68A-68D, the battery cell tabs 4540 may include a cathode tab5302 and an anode tab 5304. The cathode tab 5302 and anode tab 5304 areshown in a bent configuration illustrative of the physical configurationof the cathode tab 5302 and anode tab 5304 for when the battery cell5300 is physically attached to the flexible PCB 4100, where the cathodetab 5302 and the anode tab 5304 are placed through corresponding cutouts4140 so that the cathode tab 5302 and the anode tab 5304 each may beelectrically connected (e.g., soldered, laser welded, ultrasonic welded,etc.) to a corresponding pad 4150. In some cases, the cathode tab 5302may be made of a first material (e.g., copper) and may be clad in asecond material (e.g., aluminum). In some cases, the cathode tab may bemade of a single material (e.g., aluminum, copper, etc.). This claddingarrangement may cause a thickness and/or height of the cathode tab 5302relative to its respective inward facing surface of the PCB 4100 to begreater than a thickness or height of the anode tab 5304. The anode taband the cathode tab may be made of or include a similar electricallyconductive metal, such as copper, aluminum, nickel and the like. In theillustrative example of FIG. 68A, opposing edges of the cathode tab 5302and the anode tab 5304 may be positioned approximately 12 mm apart orwithin a range of 10 mm and 15 mm apart. Further, the cathode tab 5302and the anode tab 5304 may have a similar length (e.g., about 12.4 mm)and/or a similar width (e.g., about 4 mm), however, one or moredimensions of the cathode tab 5302 or anode tab 5304 may differ from theother within the scope of this disclosure. FIG. 68A shows a front viewof the battery cell 5300. The terms “top” 5342 and “bottom” 5344 areterms that refer to specific sides of the battery cell 5300, where thetop 5342 and bottom 5344 adjacent the front 5346 and rear sides 5348 ofthe battery cell 5300 is affixed to the flexible PCB 4100, the outwardfacing surface 5332 may be on a front 5346 of the battery cell 5300 isopposite the bottom 5344 side and faces towards an interior surface of ahousing of the CWB. FIG. 68D shows a top view of the battery cell 5300that illustrates a thickness of the battery cell 5300. FIG. 68B shows anillustrative side view of the battery cell 5300. While lithium-ionbattery cells in a pouch-cell format are discussed, other batteryformats or chemistries may be used, such as prismatic battery cells,can-type battery cells, and the like.

In some cases, connection locations for each battery cell 5300 may bemarked on the flexible PCB 4100. Additionally or alternatively, batterycell connection locations may include a rigidizing material, or may beotherwise reinforced such as via attachment of a battery cell module.Each battery cell connection location may be associated with a pair ofcutouts 4140 for the anode and cathode connections, as discussed above.Here, a battery cell module 5300 may be physically attached to thesubstrate of the flexible PCB 4100, such as by use of an adhesivematerial (e.g., glue, tape, etc.). Electrically conductive cathode andanode connection tabs 5302, 5304 may be inserted through a correspondingcutout 4140 so that the connection tabs 4540 may be welded, or otherwiseconnected to the connection pad 4150 on the rear side of the flexiblePCB 4100 to create an electrical connection between the battery cell5300 and the flexible PCB 4100. The cathode and anode connection tabs5302, 5304 may be different materials. For instance, the electricallyconductive cathode and anode connection tabs 5302, 5304 may comprise oneor more of aluminum, copper, nickel, or other materials.

FIGS. 69A-69E show illustrative views of a battery cell module 5400comprising a battery cell (e.g., the battery cell 5300) and a batterycell attenuating member 4710 (e.g. an attenuating member made of aresilient, shock absorbing material) according to aspects of thisdisclosure. In the illustrative example, the battery cell attenuatingmember 4710 may be affixed to a top surface (e.g., top 5320) of thebattery cell 5300 to form the battery cell module 5400. In some cases,the battery cell attenuating member 4710 may be affixed with glue,epoxy, tape or other adhesive substance. In some cases, as can be shownbetween the views of FIGS. 69C and 69D, the attenuating member may bealigned with a center line of the battery cell 5300. For example, one ormore center lines of the attenuating member 4710 may be aligned with oneor more corresponding center lines of the battery cell 5300. In somecases, the attenuating member may be slightly offset or from a centerline of the battery cell 5300. For example, a first edge of theattenuating member 5310 may be aligned with a corresponding edge of thebattery cell pouch, while a second opposite edge of the battery cellattenuating member 4710 may be aligned with the foil external to theopposite edge of the battery cell pouch.

FIGS. 70A and 70B show partial illustrative views of at least onebattery cell module attachments to the flexible PCBA 4500 according toaspects of this disclosure. For example, battery cell tabs (the cathodetab 5302 and the anode tab 5304) are shown in FIG. 70A as being passedthrough the cut-out 4140 and/or bent around an edge of the flexible PCB4100 and electrically and physically attached an associated bonding pad4150. FIG. 70B shows an edge view of a physical arrangement for abattery cell module 5400 attachment to the flexible PCB 4100.

Because of the compact nature of the CWB and the folded PCBA 5000, theelectrical connection between the connection pads 4150 and the batteryconnection tabs (e.g., tabs 5540A, tabs 5540B) may be minimized withrespect to the height of the overall connection relative to the inwardfacing surfaces 4520A, 4520B, as shown in FIGS. 70C and 70D. Forinstance, by using a welding technique that applies localized heat overa smaller amount of time compared to traditional soldering, the amountof material, and heat, needed to form a solid connection may be reduced.This means that the outward facing surface of the connection tab 5540may be have little to no additional material on it after being securedto the pad 4150. Further, by minimizing applied heat during theconnection process, a probability that the folded PCBA 5000, the batterycell 5300, or other component near the connection site may be damaged issimilarly reduced. In some cases, the joint may be formed using only byjoining the material of the pad 4150 and the material of the connectiontab 4540 without the addition of solder, weld filler, or any additionalmaterial. By minimizing the amount of material in the joint, the height,H1 shown in FIG. 70E, of the connection may be controlled to reduce theoverall thickness of the PCBA 4100 when folded (e.g., the folded PCBA5000). As shown in FIG. 70E, the height, H1, may be defined as thedistance between an outward facing surface 5536 of each connection tab5540A, 5540B and the rear or inward facing surface 4520A or 4520B of theflexible PCB 4100. In some cases, the joint formed by joining thematerial of the pad 4150 with the material of the connection tab 4540may be made via a process capable of minimizing the height of the joint,such that the joint thickness is much less than the thickness of theconnection tab 4540. For example, the height, H1, of the joint may bemade via a process (e.g., laser welding) such that at least a portion ofthe connection tab 4540 and/or a portion of the pad 4150 may be joinedtogether with a joint height that is less than the height of a joint ofsimilar materials made through use of a different process (e.g.,soldering). For example, the height H1 may be approximately 30% of thethickness of the connection tab 4540 or may be within a range of 10% to70%of the thickness of the connection tab 4540.

In some regions of the flexible PCB 4100, such as for battery cell5300B, each connection tab 4540 may extend through a cutout 4140 of theflexible PCB 4100 to attach to its corresponding connection pad 4150,while in other regions, connection tabs 4540 may extend from respectivebattery cell 5300 and wrap around an upper edge of the flexible PCB 4100before attaching to its corresponding connection pad 4150. For example,as shown in FIGS. 70C and 70D, battery cell 5300A that may be positionednear an edge of the flexible PCB 4100 (e.g., a battery cell may not havean adjacent battery cell positioned adjacent to it on the side of thebattery cell that has the connecting tabs) may have connection tabs5540A that extend away from the battery cell and wrap around an upperedge of the flexible PCB 4100 before extending along an opposite side ofthe flexible PCB 4100 before attaching to connection pad 4150.

FIGS. 71 and 72 show different perspective views of a battery cellmatrix or grid associated with a flexible PCBA according to aspects ofthis disclosure. For example, the flexible PCBA assembly 5600 mayinclude a number of battery cells arranged in a matrix configuration5610, such as a 5×4 matrix, with one position having an opening for aconnector interface. In some cases, the flexible PCBA 5600 may include a3-dimensional matrix configuration 5620, such as a 5×4×2 matrixconfiguration, where some matrix positions may not include battery cellmodules, but may include circuitry modules, connection modules, openspaces and/or the like. FIG. 72 shows a view of an opposite side of theflexible PCBA 5600 of FIG. 71, where positions of the matrix may befilled battery cell modules, a connector module 5710, and/or one or morecircuitry modules 5720, 5730. Considering the view of FIG. 72, a3-dimensional (e.g., a 5×4×2) battery cell matrix configuration 5620 mayinclude the 5×4 matrix configuration 5610 of FIG. 71 and the 5×4 matrixconfiguration 5700 of FIG. 72. In some cases, adjacent columns of thebattery cell matrix configuration 5700 (e.g., column 5743, column 5745)may have a spacing between about 4.5 mm to about 5.5 mm (e.g., about 5mm) and adjacent rows of the battery cell matrix 5700 (e.g., row 5742,row 4174) may have a spacing between about 6.5 mm to about 7.5 mm (e.g.,about 7 mm). The spacing between adjacent rows and/or adjacent columnsmay be determined, at least in part, based on a size and/or shape of abattery module to allow an assembled CWB to meet power, flexing, and/orsizing requirements set forth in a specification and/or standard, suchas to meet the requirements of MIL-PRF-32383/4A.

In some cases, a battery cell matrix may include only battery cells,such as a 3×3 battery cell matrix, a 4×4 battery cell matrix, a 5×4battery cell matrix, or other single-sided or double-sided matrixconfiguration within a flexible and sealed housing, where control andmonitoring circuitry may be externally connected (e.g., via a flexibleconnector, a cable, and/or the like) to the battery cell matrix, eitherwithin or external to a CWB housing. The specific matrix configurationsand spacings are given for illustrative purposes and other matrixconfigurations and spacings may be contemplated within the scope of thisdisclosure.

FIGS. 73A-73D show different side views of the flexible PCBA of FIGS. 71and 72 from a perspective of each of four different edges according toaspects of this disclosure. For example, FIG. 73A shows a 3×2 matrix ofbattery cell modules with a connector module, FIGS. 73B and 73C show 4×2and 5×2 matrices of battery cell modules, respectively, and FIG. 73Dshows a 2×2 matrix 5810 of battery cell modules, a 2×2 matrix 5820 ofbattery cell modules and circuitry modules, and a connector interface5830. FIGS. 74 and 75 show partial views of the illustrative PCBA 5600of opposite sides near the connector module 4170.

As shown in FIGS. 76 and 77, the battery cell assembly 6100 may bereceived into a housing 6160 to provide at least physical and/orenvironmental protection for the CWB 6110. The housing 6160 may includean upper housing member 6162 and a lower housing member 6164. The upperhousing member 6162 and lower housing member 6164 may be connectedtogether to form an interior cavity 6166, as shown in FIG. 76. Inaddition, the upper housing member 6162 and lower housing member 6164may be sealed together along the perimeter to protect the battery cellassembly 6100 from to prevent ingress of solid material and/or liquidmaterial. Accordingly, the CWB 6110 may meet the requirements ofMIL-PRF-32383/4A. Each housing member 6162, 6164 may be formed from apolymeric material using a molding or other technique known to oneskilled in the art.

The arrangement of the battery cell modules 6130 on the outward facingsurfaces of the flexible PCBA 4500 places the battery cell modules suchthat an outward facing surface of each battery cell module faces aninterior surface of either the upper housing member 6162 or the lowerhousing member 6164. Additionally, a plurality of battery cell shockabsorbing members may be individually attached to the outward facingsurface of each battery cell. Each battery cell attenuating member maybe positioned between the outward facing surface and one of the interiorsurfaces of the respective upper or lower housing members 6162, 6164.

As discussed above, each battery cell may be connected to the flexiblePCB 4100 using a means to reduce the height profile, while alsomaximizing the density of the matrix of the battery cells. As shown inFIG. 78, the installation process 6300 for each battery cell module 6130to the flexible PCB 4100 may include multiple steps. As noted in step6305, the battery cell module 6130 may be attached to a correspondingbattery connection location 4230 on one of the outward facing surfacesof the flexible PCB 4100. The battery cell module 6130 may be attachedusing an adhesive (i.e. liquid adhesive, double-sided tape, or othersimilar method) that is positioned between the rear side of the batterycell of the battery cell module 6130 and the corresponding outwardfacing surface. When a tape is used, the tape may have a surface areasimilar to the surface area of the rear side of the battery cell of thebattery cell 6130.

In step 6310, the cathode tab of each battery cell may be routed eitherto wrap around an edge of the flexible PCB 4100 (if the battery cellmodule 6130 is located along an edge of the flexible PCB 4100) orthrough a cut-out 4140 (if the battery cell module 6130 is located awayfrom an edge of the flexible PCB 4100). The cathode tab is then formedor bent such that the cathode tab extends substantially parallel to acorresponding inward facing surface of the flexible PCB 4100 and ontothe appropriate electrical connection pad 4150. In step 6315, anelectrical connection may then be created between the cathode tab andthe electrical connection pad 4150 or its corresponding surface coating.The electrical connection may be formed using a technique to create anelectrical connection between metal interfacing materials, such asultrasonic welding, laser welding, or other appropriate weldingtechnique. By using laser welding or ultrasonic welding, the differentmaterials such a cathode tab that includes aluminum to an ENIG surfacecoating without additional filler materials which can help minimize theheight, H1, of the tab to the rear surface of the flexible PCB 4100(e.g., an inward facing surface) of the flexible PCB 4100. In steps 6320and 6325, the steps of routing and connecting the cathode tab may berepeated for the anode tab of the battery cell module 6130 to completethe electrical connection for the battery cell 6130. In some examples,the anode tab may be routed and connected before the cathode tab. Asanother option, to accommodate a production environment, the attachmentsteps may be done as groupings such that all of the battery cell modules6130 may be affixed with adhesive first, then the tabs may be routedappropriately, and then the tabs may be have the electrical connectionsformed using the appropriate welding technique (e.g., each batteryconnection tab 4540, such as the cathode tab and/or the anode tab, maybe welded individually in a sequence until all of the electricalconnections are formed).

Electrical and electronic circuits, such as those found in a CWB, mayneed protection against electrical overloads and/or correspondingthermal runaway conditions that may cause catastrophic failure of theassociated device. This protection for the voltage distribution-typecircuits, within a CWB, may be provided by a fuse at each electricalconnection position of each of the battery cells to an internal printedcircuit board (PCB). An electric fuse consists principally of a sectionof conductor, known as a fusible element or fusible link, of suchproperties and proportions that excessive current (e.g., current above apredetermined limit) melts and thereby severs the circuit. Acharacteristic of an electric fuse is its current rating (e.g., 1 amp, 2amps, etc.), which identifies the maximum current the electric fuse canallow to pass without melting or opening (e.g., 1 amp, 2 amps, etc.).For example, a two (2) amp fuse will melt or clear if current passingthe fuse is greater than 2 amps. During assembly, as described above,electrical connection tabs (e.g., an anode tab and a cathode tab) of abattery cell may be physically and electrically connected to anelectrical connection pad on the flexible circuit board. For example,heat energy may be applied to a surface of the electrical connection padand/or a corresponding electrical connection tab via a solderingprocess, a laser welding process, or the like. In some cases, the heatenergy may be conducted along metallic traces integral to the printedcircuit board and associated with the electrical connection pad thatmay, in turn, cause heating of adjacent electrical componentselectrically and thermally connected to the electrical connection pad.In such cases, a fuse structure located adjacent to the electricalconnection pad may experience localized heating via connected metallictraces due to the process of connecting the electrical connection tab tothe electrical connection pad. In some cases, an amount of appliedthermal energy may heat the electric fuse, which may cause failure of afuse element of the electric fuse.

In an illustrative example, a trace fuse may be formed in a printedcircuit board near, and electrically connected to, an electricalconnection pad. The trace fuse may be designed to limit an amount ofcurrent to and/or from a battery cell that is physically and/orelectrically connected to the electrical connection pad. During amanufacturing process, heat energy may be applied during soldering orwelding of the battery cell's electrical connection tab(s) to itsassociated electrical connection pads on a printed circuit board.Because the metallic traces connected to the electrical connection padsare capable of conducing heat, the metallic traces may facilitate heattransfer from the electrical connection pad to adjacent components, suchas the trace fuse. In some cases, the heat transferred, such as during aduration of soldering or welding may heat the trace fuse structures,such as a fuse element. If sufficient heat is conducted to the tracefuse, the fuse element may fail (e.g., open or “blow”), thereby causinga failure of the trace fuse. Because the trace fuse is integral to theprinted circuit board, a blown trace fuse may not be repairable, therebycausing the entire printed circuit board to be scrapped. Therefore, aneed has been recognized for a fusing structure with redundant fuseelements that may be enabled when a primary fuse element has failed toensure cost-efficient manufacturing of the conformal wearable battery.

FIG. 79 illustrates a portion of the flexible printed circuit boardassembly according to aspects described herein. As discussed above, abattery cell module 5300 may be physically attached to an opposite sideof the substrate of the flexible PCB 4100, such as by use of an adhesivematerial (e.g., glue, tape, etc.). Pairs of battery cell electricalconnection tabs 7540 a, 7540 b may extend through pairs of cutouts 7140to facilitate electrical connection of a battery cell module 5300 to theflexible PCB 4100. For example, the battery cell electrical connectiontabs (e.g., an anode tab 7540 a, a cathode tab 7540 b) may be joined torespective electrical connection pads 7150 with a solder connection orwith a weld, such as by using one or more of a laser welding processand/or an ultrasonic welding process. For each battery cell module 5300,the anode tab 7540 a and the cathode tab 7540 b may be inserted througha corresponding cutout of the pair of cutouts 7140 so that the anode tab7540 a and the cathode tab 7540 b may be welded, or otherwise connected,to the connection pad 7150 on the opposite side of the flexible PCB 4100from where the battery cell module 5300 is physically attached. Thejoining of the anode tab 7540 a and the cathode tab 7540 b creates anelectrical connection between the battery cell module 5300 and theflexible PCB 4100. The anode tab 7540 a and the cathode tab 7540 b maybe made of one or more different electrically conductive materials. Forinstance, cathode tab 7540 a and the electrically conductive anodeconnection tab 7540 a may comprise one or more of aluminum, copper,nickel, or other materials.

FIG. 80 shows a portion of the electrical connections of the flexibleprinted circuit board assembly according to aspects described herein.For example, physical and electrical connections of electricalconnection tabs of two battery cells to the flexible PCB 4100 are shown.A positive terminal or tab of each battery cell (e.g., the anode tab7540 a) may be coupled to a positive connection pad 7150 a associatedwith a positive trace bus 7208 and a negative terminal or tab (e.g., thecathode tab 7540 b) of each battery cell may be coupled to a negativeconnection pad 7150 b associated with a negative trace bus 7206 suchthat the plurality of battery cell modules of the battery cell array4610 may be electrically coupled together. As discussed, the anode tab7540 a and the cathode tab 7540 b of each battery cell module 5300 arepassed through a corresponding pair of cutouts 7140 in the flexible PCB4100 to be physically and electrically connected to correspondingpositive trace pad 7150 a and negative trace pad 7150 b. Each of thepositive trace pad 7150 a and the negative trace pad 7150 b may beformed as an exposed metallic feature (e.g., a circular metallic pad) ofa conductive region formed on a layer of the flexible PCB 4100, such asthe anode connection region 7207 and the cathode connection region 7205.Different conductive regions defined on the flexible PCB 4100 may beelectrically isolated or separated from other conductive regions by aninsulating feature defined in the flexible PCB 4100. For example, thepositive trace bus 7208 may be electrically isolated from the negativetrace bus 7206 by the insulating region 7203 c. Additionally, flexibleregions of the flexible PCB 4100, such as the flex line 1125, 4125and/or bend line 1105, 4105 may include a conductive mesh 7124 a tofacilitate a flexible electrical connection on the positive trace bus7208 and a conductive mesh 7124 b to facilitate a flexible electricalconnection on the negative trace bus 7206. The conductive mesh 7124 aand 7124 b may each include a plurality of electrical pathways, where aplurality of alternative conductive paths may be used to connect regionsof the positive trace bus 7208 and the negative trace bus 7206. Should aportion of the alternate conductive paths of the conductive mesh 7124 a,7124 b be damaged, for example by a destructive penetration to the CWB,a tear, a fracture, or other such damage to the flexible PCB, otheralternative conductive pathways of the conductive mesh may be capable ofproviding electrical current around the damaged area and preventingfailure of the positive trace bus 7208 or the negative trace bus 7206.

In some cases, such as during a battery cell failure condition,disconnecting a battery cell from the power bus (e.g., the positivetrace bus 7208 and the negative trace bus 7206) may be desirable and/ornecessary. As such, a battery cell connection region 7120 may be definedfor each electrical connection. For example, the illustrative batterycell connection region 7120 may enclose the cathode connection region7205 and the negative trace pad 7150 b and may be defined by theinsulating region 7203 b. To facilitate an interruptible electricalconnection between a battery terminal (e.g., the anode tab and/or thecathode tab) of a battery cell, the battery cell connection region 7120may include one or more fusible structures, such as a redundant tracefuse structure 7122.

FIGS. 81A and 81B illustrate configurations of redundant trace fusesaccording to aspects described herein. For example, FIG. 81A shows afirst configuration of a battery cell connection region 7120 bordered byan insulating region 7203 and including a trace fuse structure 7122 anda cathode connecting region 7205 surrounding a trace pad 7250 used forforming an electrical connection and a physical connection to acorresponding electrical tab (e.g., cathode tab or anode tab) of abattery cell such as via a welding or soldering process that, e.g.,applies heat energy to the electrical connection/pad/surrounding area.The trace fuse structure 7210 may include one or more fusible elements.The illustrative trace fuse structure 7210 of FIG. 81A includes a tracefuse 7214, a redundant trace fuse 7212 and a third fusible structure7216. Each of the trace fuse 7214, the redundant trace fuse 7212 and thethird fusible structure 7216 may be separated by the insulating region7203.

In some cases, a trace fuse may be used as an integral fusible structureto electrically disconnect an individual battery cell from a power busof the CWB, such as when one or more battery cells enter a failurecondition, e.g., thermal event, a high current event, or other failureevent. In some cases, failure of a single battery cell of amulti-battery cell system can cause the whole system to fail. Forexample, failure of multiple battery cells may be induced based on afailure of a single battery cell and a resulting thermal runawaycondition. In some cases, thermal runaway conditions may be caused, atleast in part, due to heating of a battery cell due to excessivecurrents. To avoid such conditions, one or more fuses, such as the tracefuse 7214 may be used as an overcurrent protection device, such fusescan protect one or more of the battery cells of the CWB from damage dueto large current and short circuit during charging, discharging, and/ora failure condition experienced by the CWB such as a penetration event.

In an illustrative example, the trace fuse 7214 may include a trace fuseelement 7220 comprising a conductive trace electrically connecting theconductive region 7205 to an electrical circuit such as, for example,the negative trace bus 7206. The redundant trace fuse 7212 may bedesigned as a redundant fuse and may include a fuse element 7230 thatmay be electrically connected to the conductive region 7205 and may beelectrically and physically disconnected from the negative trace bus7206 by an insulating region 7203 d. To facilitate an electricalconnection of the redundant trace fuse 7212 to the electrical circuit(e.g., the negative trace bus 7206), the second fusible structure mayinclude a pair of solder pads 7232 a and 7232 b. The solder pads 7232 aand 7232 b may be connected (e.g., soldered, welded, etc.) via a jumper,wire or other conductive element to complete the electrical connectionto enable the redundant trace fuse 7212 connection between theconductive region 7206 and the negative trace bus 7206. The thirdfusible structure 7216 may include a first solder pad 7252 electricallyconnected to the conductive region 7205 and a second solder pad 7254electrically connected to an external circuit, such as the negativetrace bus 7206. In some cases, the first solder pad 7252 and the secondsolder pad 7254 may be separated by an insulating region 7203e. Thethird fusible structure may be enabled such as by soldering an externalfuse (e.g., a surface mount fuse, etc.) between the first solder pad7252 and the second solder pad 7254. The trace fuse element 7220 mayhave a length (e.g., between about 30 mils to about 200 mils) and awidth (e.g., between about 4 mils to about 70 mils) that have beencalculated such that the resistance of the trace fuse element 7220 mayprovide heating such that the trace fuse element 7220 may melt, orotherwise open, based on heating resulting from current flow when acurrent threshold has been exceeded (e.g., between about 1 amp to about10 amps). Similarly the fuse element 7230 may have a length and widthsuch that the resistance of the fuse element 7230 may provide heatingsuch that the fuse element 7230 may melt, or otherwise open, when acurrent threshold has been exceeded. One or more of the dimensions(e.g., length, width, etc.) of the fuse element 7230 may be the same asor different than the dimensions of the fuse element 7220.

FIG. 81B shows another configuration of a battery cell connection regionbordered by an insulating region 7203 and including a trace fusestructure 7310 and a conducting region 7205 surrounding a trace pad 7250used for forming an electrical connection and a physical connection to acorresponding electrical tab (e.g., cathode tab or anode tab) of abattery cell such as via a welding or soldering process. The trace fusestructure 7310 may include one or more fusible elements. Theillustrative trace fuse structure 7310 of FIG. 81B may include a tracefuse 7314, a first redundant trace fuse 7312 and a second redundanttrace fuse 7316. Each of the trace fuse 7314, the first redundant tracefuse 7312 and a second redundant trace fuse (e.g., the redundant tracefuse 7316) of the trace fuse structure 7310 may be separated by at leasta portion of the insulating region 7203.

In some cases, the trace fuse 7214 of the structure 7210 FIG. 81A and/orthe trace fuse 7314 of the structure 7310 of FIG. 81B may be used as anemergency disconnect circuit for disconnecting a battery cell from thepositive trace bus and/or the negative trace bus in the event of abattery cell failure and/or a failure of the CWB. For example, if abattery cell current exceeds a current rating threshold of the tracefuse element 7220 of the trace fuse 7214 or the trace fuse element 7320of the trace fuse 7314, the trace fuse element 7220 and/or 7320 may meltor otherwise open. In some cases, if a temperature of the trace fuseelement 7220 or a temperature near the trace fuse element 7220, thetrace fuse element 7220 may melt or otherwise open. In some cases, theexcessive heat may occur without an excessive current condition. Forexample, an excessive heat condition may be experienced locally to aparticular trace fuse, such as during a process of soldering and/orwelding a battery tab to an adjacent trace pad. For example, when abattery tab is soldered (or welded) to the trace pad 7250, heatingapplied to the battery tab and the trace pad 7250 may be thermallyconducted to adjacent metal features of the flexible PCB 4100. In somecases, excessive heat may be applied to the trace pad 7250 and/orheating may be applied for a longer than normal duration. The excessiveheat may, in turn, be enough to heat the trace fuse element 7220 of thetrace fuse 7214 beyond its thermal capacity, thereby causing the fuse toopen. If no alternative conductive path existed between the conductiveregion 7205 and an associated trace bus of the flexible PCB 4100, theflexible PCB 4100 may need to be scrapped, even for as little as onefailed trace fuse 7214. Such losses reduce manufacturing throughput andefficiencies and cause associated costs to rise. If enough flexible PCBsare lost during production, a time delay may be occurred if additionalreplacement flexible PCBs must be sourced.

As a solution, one or more redundant trace fuse elements, such as theredundant trace fuse 7212 and the third fusible structure 7216 of thetrace fuse structure 7210 shown in FIG. 81A may be used. In some cases,an alternative trace fuse structure 7210 with a different configurationof trace fuses and/or trace fuse structures may be used, such as thetrace fuse structure 7310 of FIG. 81B. To enable operation of theredundant trace fuse 7212, a jumper or other conductive element may besoldered, welded, or otherwise electrically connected between the solderpads 7232 a and 7232 b to bypass the insulating region 7203 d. Onceconnected, an electrical connectivity between the conductive region 7205and, for example, the negative trace bus 7206 may be measured tovalidate that the redundant trace fuse 7212 is enabled as a trace fuseproviding protection for the associated battery cell tab electricalconnection. Similarly, if the third fusible structure 7216 is desiredfor use as a fusible link between the conductive region 7205 and thenegative trace bus 7206, a fuse, such as a surface mount fuse, may besoldered or otherwise connected between the first solder pad 7252 andthe second solder pad 7254. After which, electrical connectivity betweenthe conductive region 7205 and the negative trace bus 7206 may betested.

FIG. 82 shows an illustrative method of use of a redundant trace fusestructure according to aspects described herein. For example, theillustrative installation process 7400 that may be used to establishelectrical connections between a battery cell 5300 to the flexible PCB4100. For example, at 7410, a battery cell tab (e.g., the anode tab 7540a, the cathode tab 7540 b) may be electrically and physically connectedto an electrical connection pad (e.g., the electrical connection pad7540 a, the electrical connection pad 7150 b), such as by using asoldering or welding process. Once connected, a measurement may be takenat 7420 to verify that an electrical connection exists between theelectrical connection pad and the corresponding trace bus, such asbetween the electrical connection pad 7540 a and the positive trace bus7208 and/or electrical connection pad 7150 b and the negative trace bus7206. If, at 7425, the electrical connection remains between theelectrical connection pad 7540 a and the positive trace bus 7208 and/orelectrical connection pad 7150 b and the negative trace bus 7206, theelectrical connection of the battery cell 5300 to the flexible PCB 4100is complete and that the trace fuse 7214 remains whole and the process7400 completes for a particular tab of a battery cell at 7480. Oncecomplete, the installation process 7400 may be repeated for each tab ofthe different battery cells of the CWB.

In some cases, the process 7400 may be performed in parallel for boththe anode tab and the cathode tab for a particular battery cell. In somecases, the process 7400 may be completed for each electrical connectiontab individually. In some cases, the process 7400 may be performed forgroupings of battery cells of the plurality of battery cells containedin the CWB. For example, a row or column of battery cells may beconnected by welding or soldering the battery cell tabs as a group,where continuity tests may be performed sequentially for each batterycell tab of the connected group of battery cells.

Returning to 7425, if an open circuit is detected indicating that thetrace fuse 7214 has blown, a secondary trace fuse element may beenabled. For example, at 7430, a jumper may be installed (e.g.,soldered, welded, or the like) between the solder pads 7232 a and 7232 bto complete an electrical circuit to enable the secondary trace fuseelement, such as to enable a secondary fuse element comprising theredundant trace fuse 7212. Once the jumper has been installed, ameasurement may be taken at 7440 to verify that an electrical continuityexists for the electrical circuit between the electrical connection pad7150 a and the corresponding trace bus, such as between the electricalconnection pad 7150 a and the positive trace bus 7208 and/or electricalconnection pad 7150 b and the negative trace bus 7206. If, at 7445, theelectrical connection remains between the electrical connection pad 7150a and the positive trace bus 7208 and/or electrical connection pad 7150b and the negative trace bus 7206, the electrical connection of thebattery cell 5300 to the flexible PCB 4100 is complete and that theredundant trace fuse 7212, 7312 remains whole and the process completesfor a particular tab of a battery cell at 7480. Once complete, theprocess 7400 may be repeated for each tab of the different battery cellsof the CWB.

If, at 7455, the continuity test results in a reading confirming an opencircuit condition, the redundant trace fuse 7212 has opened so that at7455, a check may be performed to identify a configuration of a thirdfuse element to identify whether the third fuse element comprises aredundant trace fuse 7216, 7316 or another structure configured toreceive a fusible link, such as a pair of electrical pads as shown inthe third fusible structure 7216. If third trace fuse is identified, ajumper may be installed (e.g., soldered, welded, or the like) betweenthe solder pads 7252 a and 7252 b to complete an electrical circuit toenable the third trace fuse element 7216, such as to enable a redundantfuse element comprising the third trace fuse element 7216. Once thejumper has been installed, a measurement may be taken to verify that anelectrical continuity exists for the electrical circuit between theelectrical connection pad and the corresponding trace bus, such asbetween the electrical connection pad 7150 a and the positive trace bus7208 and/or electrical connection pad 7150 b and the negative trace bus7206. If at 7465, the electrical connection remains between theelectrical connection pad 7150 a and the positive trace bus 7208 and/orelectrical connection pad 7150 b and the negative trace bus 7206, theelectrical connection of the battery cell 5300 to the flexible PCB iscomplete and that the redundant trace fuse 7216 remains whole and theprocess completes for a particular tab of a battery cell at 7480. If,however, at 7465 the continuity test identifies a discontinuity or opencircuit between the electrical connection pad and the associated tracebus, the third trace fuse 7316 has failed, causing the flexible printedcircuit board assembly to fail and a board failure process may proceedat 7490. In some cases, reusable components may be removed from thefailed PCBA for future use.

Returning to 7455, if a trace fuse structure similar to the thirdfusible structure 7216 is identified, an external fuse may be installed(e.g., soldered, welded, etc.) at 7430 to complete the electricalcircuit between the electrical connection pad 7150 a and thecorresponding trace bus, such as between the electrical connection pad7150 a and the positive trace bus 7208 and/or electrical connection pad7150 b and the negative trace bus 7206. Once the external fuse has beeninstalled, a measurement may be taken to verify that an electricalcontinuity exists for the electrical circuit between the electricalconnection pad 7150 a and the corresponding trace bus, such as betweenthe electrical connection pad 7150 a and the positive trace bus 7208and/or electrical connection pad 7150 b and the negative trace bus 7206.If at 7465, the electrical connection remains between the electricalconnection pad 7150 a and the positive trace bus 7208 and/or electricalconnection pad 7150 b and the negative trace bus 7206, the electricalconnection of the battery cell 5300 to the flexible PCB 4100 is completeand that the redundant fusible structure 7216 remains whole and theprocess completes for a particular tab of a battery cell at 7480. If,however, at 7465 the continuity test identifies a discontinuity or opencircuit between the electrical connection pad and the associated tracebus, and the fuse element remains whole, a board failure may beidentified causing the flexible printed circuit board assembly to failand a board failure process may proceed at 7490.

A CWB assembly may include an array of a first quantity of battery cellsdisposed adjacent to one another in a horizontal direction and a secondquantity of battery cells disposed adjacent to one another in a verticaldirection. The array of battery cells may be arranged in a grid-likepattern. Each of the battery cells may be encased or housed in a batterycell housing separate from other battery cells. A battery cell asdescribed herein may include a plurality of individual battery cellelements that are electrically connected together to form a compoundbattery cell that electrically performs as a single unit. Each of thebattery cell housings may be physically connected to adjacent batterycell housings by flexible elements (e.g., a flexible printed circuitboard), thereby facilitating a surface outline or shape of the array ofbattery cells to generally conform to a surface outline or shape of auser wearing the CWB assembly. One or more of the battery cell housingsmay include a positive-charge electrical terminal and a negative-chargeelectrical terminal that are electrically connected with the batterycell within an interior of the battery cell housing and provideelectrical power to electrical devices disposed exterior to the batterycell housing. Electrical terminals of a plurality of the battery cellsin the array of battery cells may be connected together to routeelectrical current through the plurality of the battery cells and a setof positive-charge and negative-charge electrical terminals that areshared among the plurality of the battery cells. The positive-chargeelectrical terminal and the negative-charge electrical terminal mayprovide an electrical current that passes through an electricallyconductive path, for example, through an electronic device, via transferof electrons through the electrically conductive path between thepositive-charge electrical terminal and the negative-charge electricalterminal on the exterior of the battery cell housing. The CWB assemblymay include a set of positive-charge and negative-charge electricalterminals that are shared among the plurality of the battery cells ofthe array of battery cells. The plurality of the battery cells may beelectrically coupled together, for example, in series or in parallel.

While aspects of the disclosure have been described with reference tobattery cells and/or a CWB comprising battery cells, arrangements andmethods as described herein may also be applied to other devices andsystems having a flexible PCBA to maximize space within a housing. Forexample, the arrangements and methods described herein may apply to anyelectronic device disposed within a housing for which maximizing usableinterior space within a housing by folding a flexible PCBA within theavailable interior space is desired. Examples of such electronic devicesmay include underwater cameras, sonar devices, radar devices, lidardevices, emergency radio beacons, satellite communications devices,terrestrial wireless communications devices, global positioning system(GPS) receivers, electronic environmental sensor devices, electronicmedical devices, computing processors, solar cell based power generationdevices, wave motion based power generation devices, fuel cell basedpower generation devices, battery charging controllers, and/or portablechemical batteries for powering electronic or electrical devices.

In an illustrative example, a conformal wearable battery may include aplurality of battery cells and a flexible printed circuit board assembly(PCBA). The flexible PCBA may include a plurality of physical connectionsections disposed in a grid like pattern, wherein each of the pluralityof battery cells is physically affixed to the flexible PCBA at acorresponding physical connection section of the plurality of physicalconnection sections, a bend axis disposed between two parallel physicalconnection sections, wherein the bend axis facilitates folding of theflexible PCBA in half. Additionally, the flexible PCBA may include aplurality of first cut-outs disposed along the bend axis, wherein eachfirst cut-out of the plurality of first cut-outs is disposed parallel tothe bend axis and a plurality of second cut-outs disposed across thebend axis, wherein each second cut-out of the plurality of secondcut-outs are disposed perpendicular to the bend axis.

The conformal wearable battery of the illustrative example may include afirst plurality of electrical connections each connecting a cathode of acorresponding battery cell of the plurality of battery cells and secondplurality of electrical connections each connecting an anode of thecorresponding battery cell of the plurality of battery cells toelectrical conductors of the flexible printed circuit board assembly.

The conformal wearable battery may include a plurality of battery cells,at least one circuitry module configured to control and monitor chargingand discharging of the plurality of battery cells, and a flexibleprinted circuit board assembly (PCBA). The flexible PCBA may include aplurality of physical connection sections disposed in a grid likepattern, wherein each of the plurality of battery cells and the at leastone circuitry module is physically affixed to the flexible PCBA at acorresponding physical connection section of the plurality of physicalconnection sections.

The conformal wearable battery of the illustrative example may include aflexible PCBA that includes a first plurality of electrical connectionseach connecting a cathode of a corresponding battery cell of theplurality of battery cells and second plurality of electricalconnections each connecting an anode of the corresponding battery cellof the plurality of battery cells to electrical conductors of theflexible printed circuit board assembly.

The conformal wearable battery of the illustrative example may include aplurality of battery cells and at least one circuitry module that, whenaffixed to the flexible PCBA, forms a matrix of physical components. Thematrix of physical components may be a matrix of at least two rows andat least two columns.

The conformal wearable battery of the illustrative example may furtherinclude at least one connector configured to provide an electrical powerconnection from internal circuitry of the conformal wearable battery toan external device to be powered.

The conformal wearable battery of the illustrative example may includethe plurality of battery cells, where the at least one connector, andthe at least one circuitry module, when affixed to the flexible PCBA,comprises a matrix of physical components.

The conformal wearable battery of the illustrative example may comprisea bend axis that is a center of the grid like pattern of the physicalconnection sections when the flexible PCBA is unfolded. The conformalwearable battery of the illustrative example may include a flexible PCBAhaving each of the plurality of battery cells physically attached to afirst side of the flexible PCBA. The conformal wearable battery of theillustrative example may include the flexible PCBA having each of theplurality of battery cells physically attached to a first side of theflexible PCBA and each of the plurality of battery cells electricallyconnected to the flexible PCBA on a second side of the flexible PCBAthat is opposite the first side. The conformal wearable battery of theillustrative example may include the flexible PCBA having the pluralityof battery cells disposed on an outside surface of the flexible PCBA,when the flexible PCBA is in a folded configuration.

The conformal wearable battery of the illustrative example may include aplurality of battery cells that are arranged in a three-dimensional gridpattern. The conformal wearable battery of the illustrative example mayinclude a sealed flexible housing wherein the flexible PCBA is disposedwithin an interior cavity of the sealed flexible housing and wherein theflexible PCBA is in a folded configuration.

An illustrative system may include a plurality of battery cell modulesand a flexible printed circuit board assembly (PCBA). The flexible PCBAmay further include a plurality of battery cell connection sectionsdisposed in a grid-like pattern along a first surface of the flexiblePCBA where each of the plurality of battery cell modules is electricallyattached to the flexible PCBA on a second surface of the flexible PCBAin a grid-like pattern, wherein the second surface is opposite the firstsurface.

The illustrative system may further include a housing, wherein theflexible PCBA, when in a folded configuration, is located within thehousing.

The illustrative system may include a plurality of battery cell modules,where each of the plurality of battery cell modules includes a batterycell and an attenuating member made of a resilient material. Eachbattery cell may be a lithium-ion battery cell. The illustrative systemmay include a plurality of battery cells arranged in a three-dimensionalgrid pattern when the flexible PCBA is in a folded configuration.

An illustrative flexible printed circuit board assembly (PCBA) mayinclude a plurality of battery modules physically affixed to theflexible PCBA, where the plurality of battery modules is arranged in agrid-like pattern and a bend axis near an approximate mid-point of theflexible PCBA. When the flexible PCBA is bent along the bend axis, theflexible PCBA is in a folded configuration and, when the flexible PCBAis in a folded configuration, the plurality of battery modules isdisposed in a three-dimensional grid-like pattern.

The illustrative flexible PCBA may include a plurality of flexiblesections, wherein the flexible sections allow for the flexible PCBA toflex between adjacent rows and adjacent columns of battery modules. Theillustrative flexible PCBA may include at least one circuitry modulethat comprises a portion of the grid-like pattern.

A conformal wearable battery may include a plurality of battery cellsand a flexible printed circuit board (PCB). In some cases, each batterycell may include a pair of electrically conductive elements thatcorrespond to either a cathode or an anode of each battery cell. Theflexible PCB may include a plurality of physical connection sectionsdisposed in a grid like pattern on a first side of the flexible PCB,were each of the plurality of battery cells may be disposed associatedwith a corresponding physical connection section of the plurality ofphysical connection sections. The flexible PCB may include a pluralityof electrical connection pads linearly disposed on a second sideopposite the first side of the flexible PCB, where the plurality ofelectrical connection pads may include an electrically conductivesurface coating. The electrically conductive surface coating maycomprise an electroless nickel immersion gold (ENIG) surface coatingand/or a lead-free immersion silver surface coating.

In some cases, the pair of electrically conductive elements may extendsubstantially parallel to and along the second side of the flexible PCBand each of the electrically conductive elements may be connected to acorresponding electrical connection pad of the plurality of electricalconnection pads on the second side of the flexible PCB forming anelectrical connection.

In some cases, the conformal wearable battery may include a plurality ofbattery cells that may be configured as pouch cell packaged polymerlithium-ion batteries. Each battery cell of the plurality of batterycells may be physically attached to the first side of the flexible PCB.

In some cases, the flexible PCB of the conformal wearable battery mayinclude a plurality of cutouts extending through the flexible PCB,wherein at least one cutout of the plurality of cutouts is locatedadjacent to an electrical connection pad of the plurality of electricalconnection pads. Each conductive element of the pair of electricallyconductive elements may extend through a corresponding cutout of theplurality of cutouts. In some cases, the electrical connection betweeneach electrically conductive element of the pair of electricallyconductive elements and the corresponding electrical connection pad ofthe plurality of electrical connection pads may be joined with a weld,such as by using one or more of a laser welding process and/or anultrasonic welding process.

In some cases, a connection pad of the plurality of electricalconnection pads may have a width that is within a range of 1.8 times and3 times a width of an electrically conductive element of the pair ofelectrically conductive elements and/or a height electrical connectionmay be within a range of 10% to 70% of a thickness of an electricallyconductive element of the pair of electrically conductive elements.

In some cases, a system may include a first plurality of battery cells,wherein a first battery cell of the first plurality of battery cellincludes a first pair of electrically conductive elements and a secondplurality of battery cell, wherein a second battery cell of the secondplurality of battery cell includes a second pair of electricallyconductive elements, and may also include a flexible printed circuitboard (PCB). The flexible PCB may include a plurality of battery cellconnection sections disposed in a grid-like pattern along a firstsurface of the flexible PCB, a plurality of cutouts disposed adjacentand parallel to an edge of the plurality of battery cell connectionsections, where the plurality of cutouts is arranged as multiple pairsof cutouts arranged adjacent a majority of the plurality of battery cellconnection sections. The flexible PCB may also include a plurality ofelectrical connection pads disposed on a second surface of the flexiblePCB opposite the first surface, where a majority of the plurality ofelectrical connection pads may be arranged adjacent the plurality ofcutouts and the plurality of electrical connection pads may include anelectrically conductive surface coating. In some cases, an electricallyconductive element of the first pair of electrically conductive elementsmay wrap around an edge of the flexible PCB and may extend along thesecond surface of the flexible PCB. The electrically conductive elementof the first pair of electrically conductive elements may connect to acorresponding electrical connection pad of the plurality of electricalconnection pads forming a first electrical connection and anelectrically conductive element of the second pair of electricallyconductive elements may extend through a cutout of the plurality ofcutouts such that each electrically conductive element of the secondpair of electrically conductive elements connects to a correspondingelectrical connection pad of the plurality electrical connection padsforming a second electrical connection.

In some cases, the system may further include the first electricalconnection between the electrically conductive element of the first pairof electrically conductive elements and the corresponding electricalconnection pad of the plurality of electrical connection pads may bejoined with a weld, such as by using a laser welding process and/orusing an ultrasonic welding process. In some cases, the connection padof the plurality of electrical connection pads may have a circular shapewith a diameter that is within a range of 1.8 times and 3 times a widthof an electrically conductive element of the pair of electricallyconductive elements.

In some cases, a flexible printed circuit board assembly (PCBA) mayinclude a flexible printed circuit board (PCB) that may include a firstside and a second side opposite the first side. The flexible PCBA mayfurther include a plurality of electrical connection pads disposed onthe second side of the flexible PCB, where the plurality of electricalconnection pads may be arranged in multiple pairs of electricalconnection pads and the plurality of electrical connection pads mayinclude an electrically conductive surface coating. In some cases, theflexible PCBA may include a plurality of cutouts linearly disposed inthe flexible PCB and adjacent to corresponding electrical connectionpads and a plurality of battery cell modules physically affixed to thefirst side of the flexible PCB, were the plurality of battery cellmodules may be arranged in a grid-like pattern and may include pouchcell packaged polymer lithium-ion material. In some cases, each batterycell module of the plurality of battery cell modules may include a pairof electrically conductive elements that extend substantially parallelto the second side of the flexible PCB and connect to correspondingelectrical connection pads of the plurality of electrical connectionpads forming an electrical connection for each battery cell module. Insome cases, the electrical connection between each electricallyconductive elements of the pair of electrically conductive elements andthe corresponding electrical connection pads of the plurality ofelectrical connection pads may be formed using a welding process. Insome cases, a connection pad of the plurality of electrical connectionpads may have a circular shape with a diameter that is within a range of1.8 times and 3 times a width of an electrically conductive element ofthe pair of electrically conductive elements. In some cases, eachelectrical connection pad of the plurality of electrical connection padsmay include an electroless nickel immersion gold (ENIG) surface coating.

A molded housing may enclose an electronic component and include anelectrically conductive contact component embedded within an exteriorwall to conduct electricity between an interior and an exterior of thecasing. The contact component may include two knurled areas separated bya recessed groove. The knurled areas and recessed groove may be coplanarwith the exterior wall. The knurled areas and recessed groove may forman interface with the molded casing to seal the casing against ingressof liquid into the interior. The molded casing may include an upperhousing and a lower housing formed from a combination of a rigid memberand a flexible member. The rigid member may have a plurality of rigidregions, and the flexible member may have a plurality of flexibleregions formed between neighboring rigid regions. The flexible membermay be molded onto the rigid member using a two-shot injection moldingprocess. In some examples, the contact component may be secured to acontact carrier, where the contact carrier is then secured to theexterior housing.

A molded housing may enclose an electronic component and include anelectrically conductive contact component embedded within an exteriorwall to conduct electricity between an interior and an exterior of thecasing. The contact component may include two knurled areas separated bya recessed groove. The knurled areas and recessed groove may be coplanarwith the exterior wall. The knurled areas and recessed groove may forman interface with the molded casing to seal the casing against ingressof liquid into the interior. The molded casing may include an upperhousing and a lower housing formed from a combination of a rigid memberand a flexible member. The rigid member may have a plurality of rigidregions, and the flexible member may have a plurality of flexibleregions formed between neighboring rigid regions. The flexible membermay be molded onto the rigid member using a two-shot injection moldingprocess. In some examples, the contact component may be secured to acontact carrier, where the contact carrier is then secured to theexterior housing.

A flexible printed circuit board assembly (PCBA) for a conformalwearable battery (CBB) includes attachment sections for a plurality ofbattery cells that are arranged in a grid-like pattern on a same side ofthe flexible PCBA. The flexible PCBA is configured to fold along a bendaxis so that the flexible PCBA is folded approximately in half. Toreduce mechanical stresses placed on the flexible PCBA when folding theflexible PCBA along the bend axis, the flexible PCBA includes aplurality of cut-outs dispersed along the bend axis and parallel toadjacent battery cells. The CWB is configured to flex during use. Theflexible PCBA includes a plurality of cut-outs disposed perpendicular tothe bend axis, between adjacent rows of battery cells, and on the bendaxis to relieve mechanical stresses applied to a bent portion of theflexible PCBA when the CWB is flexed during use.

A battery system that is formed from a plurality of battery cellsarranged on a flexible printed circuit card, where the flexible printedcircuit card is folded along an axis forming an upper and lower portionof the flexible circuit card. A visco-elastic shock-absorbing memberinstalled between the upper and lower portion of the flexible circuitcard. Each battery cell may also have a visco-elastic shock-absorbingmember that is attached individually to each battery cell of theplurality of battery cells.

A matrix of battery cell modules includes a flexible printed circuitboard assembly (PCBA) for a conformal wearable battery (CWB) with aplurality of attachment sections for each of a plurality of batterycells that are arranged in a grid-like pattern on a same side of theflexible PCBA. Each battery cell may be joined with a flexible PCB via awelding process. The flexible PCBA is configured to fold along a bendaxis so that the flexible PCBA is folded approximately in half. Whenaffixed to the flexible PCBA, the plurality of battery cell modules anda circuitry module form a grid of physical components. When folded, theflexible PCBA forms a three-dimensional grid of physical componentscomprising at least the battery cell modules.

Aspects of the disclosure have been described in terms of illustrativeexamples thereof. Numerous other examples, modifications, and variationswithin the scope and spirit of the appended claims will occur to personsof ordinary skill in the art from a review of this disclosure. Forexample, one or more of the steps depicted in the illustrative figuresmay be performed in other than the recited order, and one or moredepicted steps may be optional in accordance with aspects of thedisclosure.

Many illustrative embodiments are listed below in accordance with one ormore aspects disclosed herein. Although many of the embodiments listedbelow are described as depending from other embodiments, thedependencies are not so limited. For example, embodiment #5 (below) isexpressly described as incorporating the features of embodiment #1(below), however, the disclosure is not so limited. For example,embodiment #5 may depend any one or more of the preceding embodiments(i.e., embodiment #1, embodiment #2, embodiment #3, and/or embodiment#4). Moreover, that any one or more of embodiments #2-#6 may beincorporated into embodiment #1 is contemplated by this disclosure.Likewise, any of embodiments #1, 8, and 16 may be combined with one ormore of the features recited in embodiments #2-8, 9-15, and/or 17-20.Further likewise, any of embodiments #21, 32, and 39 may be combinedwith one or more of the features recited in embodiments #22-31, 33-37,and 40. Further likewise, any of embodiments #41, 49, 60 may be combinedwith one or more of the features recited in embodiments #42-48 and#50-59. Further likewise, any of embodiments #61, 70, and 76 may becombined with one or more of the features recited in embodiments #62-69,71-75, and 77-80. Further likewise, any of embodiments #81, 92, 97, 105,and 110 may be combined with one or more of the features recited inembodiments #82-91, 93-97, 98-104, 106-109, and 111-115. Furtherlikewise, any of embodiments #116, 128, and 133 may be combined with oneor more of the features recited in embodiments #117-127, 129-132, and134. Further likewise, any of embodiments #135, 140, 145, and 154 may becombined with one or more of the features recited in embodiments#136-129, 142-144, and 146-153. In addition, that any one or more of thefeatures in embodiments #1, 6, 16, 21, 32, 39, 41, 49, 60, 61, 70, 76,81, 92, 97, 105, 110, 116, 128, 133, 135, 140, 145, and 154 may becombined is contemplated by this disclosure. Moreover, that any one ormore of the features in embodiments #1-154 can be combined iscontemplated by this disclosure.

Embodiment #1. A conformal wearable battery comprising:

a plurality of battery cells arranged in a grid-like pattern, whereinthe plurality of battery cells comprise a positive terminal and anegative terminal to provide electricity through a transfer of electronsbetween the positive terminal and negative terminal;

a housing with an interior cavity that receives the plurality of batterycells;

a conductive region coupled to one or more of the positive terminal andthe negative terminal, wherein the electricity is provided from one ormore of the plurality of battery cells to the conductive region; and

a contact component having a front portion and a rear portion, whereinthe contact component comprises an electrically conductive material,wherein the front portion includes an outward facing surface and aperimeter region surrounding the outward facing surface, wherein theoutward facing surface is accessible from outside of the interior cavityof the housing and the rear portion has an inward facing surface;

wherein the contact component is connected to the conductive region; andwherein the perimeter region of the outward facing surface is secured tothe housing forming a sealed edge to prevent ingress of liquid into theinterior cavity.

Embodiment #2. The conformal wearable battery of Embodiment #1, furthercomprising a contact carrier that encases the rear portion of thecontact component, wherein the contact carrier is secured to thehousing.

Embodiment #3. The conformal wearable battery of Embodiment #2, whereinthe contact carrier is secured to the housing between a rear surface ofa sidewall of the housing and a rear flange that is spaced rearward ofthe rear surface.

Embodiment #4. The conformal wearable battery of Embodiment #3, whereina first plug extends from the rear surface of the sidewall through anopening in the contact carrier to the rear flange of the housing.

Embodiment #5. The conformal wearable battery of Embodiment #1, whereinthe electrically conductive material is formed from at least onematerial selected from brass, gold, copper, silver, aluminum, steel, ora combination thereof.

Embodiment #6. The conformal wearable battery of Embodiment #1, whereinthe perimeter region includes a groove and the rear portion includes atextured region and a threaded female element.

Embodiment #7. The conformal wearable battery of Embodiment #6, whereinthe textured region includes a plurality of angled gear teeth, andwherein the contact component includes an opening that receives aconductive element to create a connection between the conductive regionand the contact component.

Embodiment #8. A conformal wearable battery comprising:

a plurality of battery cells comprising a positive terminal and anegative terminal to provide electricity through a transfer of electronsbetween the positive terminal and negative terminal;

a housing that includes a first shell and a second shell, wherein thefirst shell connects to the second shell to form an interior cavity thatreceives the plurality of battery cells;

a conductive region coupled to one or more of the positive terminal andthe negative terminal, wherein the electricity is provided from one ormore of the plurality of battery cells to the conductive region;

a first contact carrier that secures a first electrically conductivecontact component, wherein the first contact carrier is secured to thefirst shell; and

the first contact component having a front portion and a rear portion,wherein the front portion includes an outward facing surface and aperimeter region surrounding the outward facing surface, wherein theoutward facing surface is accessible from outside of the interior cavityof the housing; and

wherein the first contact component is connected to the conductiveregion.

Embodiment #9. The conformal wearable battery of Embodiment #8, whereinthe first contact carrier is secured to the housing between a first rearsurface of a first sidewall of the first shell and a first rear flangethat is spaced rearward of the first rear surface.

Embodiment #10. The conformal wearable battery of Embodiment #9, whereina first plug extends from the first rear surface of the first sidewallthrough an opening in the first contact carrier to the first rear flangeof the first shell.

Embodiment #11. The conformal wearable battery of Embodiment #10,wherein the first plug, the first rear flange, and the first sidewallare a single unitary member.

Embodiment #12. The conformal wearable battery of Embodiment #8, whereina sidewall of the first shell surrounds the perimeter region of thefirst contact component and the first contact carrier surrounds atextured region of the first contact component.

Embodiment #13. The conformal wearable battery of Embodiment #9, whereinthe first rear flange includes an opening to allow access to an inwardfacing surface of the first contact component.

Embodiment #14. The conformal wearable battery of Embodiment #9, whereina connector plate configured to receive a connector is secured between asecond rear surface of a second sidewall of the first shell and a secondrear flange, and

-   -   wherein a second plug extends from the second rear surface        through an opening in the connector plate to the second rear        flange.

Embodiment #15. The conformal wearable battery of Embodiment #8, furthercomprising a second contact carrier, wherein the first contact carriersecures the first contact component and a second electrically conductivecontact component, and the second contact carrier secures a thirdelectrically conductive contact component and a fourth electricallyconductive contact component.

Embodiment #16. A system comprising:

an electronic component to provide an electrical signal, wherein theelectronic component comprises a plurality of battery cells;

a housing that includes an interior cavity that receives the electroniccomponent;

a conductive region coupled to the electronic component, wherein theelectrical signal is provided from the electronic component to theconductive region; and

an electrically conductive contact component having a front portion anda rear portion, wherein the front portion includes an outward facingsurface and a perimeter region surrounding the outward facing surface,wherein the outward facing surface is accessible from outside of theinterior cavity of the housing and the rear portion has an inward facingsurface,

wherein the contact component is connected to the conductive region; and

wherein the front portion is partially encased by a first material thatforms a sidewall of the housing and the rear portion is partiallyencased by a second material, wherein the first material has a lowerdurometer than the second material.

Embodiment #17. The system of Embodiment #16, wherein the electroniccomponent comprises a battery charging controller and a computingprocessor.

Embodiment #18. The system of Embodiment #16, wherein the perimeterregion of the contact component includes a groove, and wherein the rearportion includes a textured region and a threaded female element.

Embodiment #19. The system of Embodiment #18, wherein the contactcomponent includes a threaded opening that receives a conductive elementto create a direct connection between the conductive region and thecontact component.

Embodiment #20. The system of Embodiment #19, wherein the rear portionof the contact component is secured to a contact carrier that is formedfrom the second material.

Embodiment #21. A conformal wearable battery comprising:

a plurality of battery cells; and

a flexible printed circuit board assembly (PCBA) comprising:

-   -   a plurality of physical connection sections disposed in a grid        like pattern, wherein each of the plurality of battery cells is        physically affixed to the flexible PCBA at a corresponding        physical connection section of the plurality of physical        connection sections;    -   a bend axis disposed between two parallel physical connection        sections, wherein the bend axis facilitates folding of the        flexible PCBA in half;    -   a plurality of first cut-outs disposed along the bend axis,        wherein each first cut-out of the plurality of first cut-outs is        disposed parallel to the bend axis; and    -   a plurality of second cut-outs disposed across the bend axis,        wherein each second cut-out of the plurality of second cut-outs        are disposed perpendicular to the bend axis.

Embodiment #22. The conformal wearable battery of Embodiment #21,wherein the flexible PCBA comprises a first plurality of electricalconnections each connecting a cathode of a corresponding battery cell ofthe plurality of battery cells and second plurality of electricalconnections each connecting an anode of the corresponding battery cellof the plurality of battery cells to electrical conductors of theflexible printed circuit board assembly.

Embodiment #23. The conformal wearable battery of Embodiment #21,wherein the bend axis comprises a center of the grid like pattern of thephysical connection sections.

Embodiment #24. The conformal wearable battery of Embodiment #21,wherein each first cut-out of the plurality of first cut-outs isrectangular-shaped, wherein a longer edge of each first cut-out isdisposed parallel to the bend axis.

Embodiment #25. The conformal wearable battery of Embodiment #21,wherein each corner of each first cut-out of the plurality of firstcut-outs is rounded.

Embodiment #26. The conformal wearable battery of Embodiment #21,wherein each second cut-out of the plurality of second cut-outscomprises a first semi-circular section, a second semi-circular sectionand a rectangular section.

Embodiment #27. The conformal wearable battery of Embodiment #26,wherein the rectangular section is disposed between the firstsemi-circular section and the second semi-circular section.

Embodiment #28. The conformal wearable battery of Embodiment #26,wherein the rectangular section is disposed laterally across the bendaxis, wherein a mid-point of the rectangular section is located near thebend axis.

Embodiment #29. The conformal wearable battery of Embodiment #21,wherein each of the plurality of battery cells is physically attached toa first side of the flexible PCBA.

Embodiment #30. The conformal wearable battery of Embodiment #21,wherein the plurality of battery cells are disposed on an outsidesurface of the flexible PCBA, when the flexible PCBA is in a foldedconfiguration.

Embodiment #31. The conformal wearable battery of Embodiment #21,further comprising a sealed flexible housing wherein the flexible PCBAis disposed within an interior cavity of the sealed flexible housing andwherein the flexible PCBA is in a folded configuration.

Embodiment #32. A system comprising:

a plurality of battery cell modules;

a flexible printed circuit board assembly (PCBA) comprising:

-   -   a plurality of battery cell connection sections disposed in a        grid-like pattern along a first surface of the flexible PCBA;    -   a bend axis configured to divide the flexible PCBA in half when        the flexible PCBA is in a folded configuration; and    -   a plurality of cut-outs disposed along the bend axis, wherein        each of the plurality of cut-outs reduce a bending force placed        on the flexible PCBA when a flexing force is applied to the        flexible PCBA.

Embodiment #33. The system of Embodiment #32, wherein the plurality ofcut-outs comprises:

a plurality of first cut-outs having a first shape; and

a second plurality of cut-outs having a second shape.

Embodiment #34. The system of Embodiment #33, wherein the first shapecomprises a substantially rectangular shape having rounded corners.

Embodiment #35. The system of Embodiment #33, wherein the second shapecomprises at least one semi-circular section and a rectangular section.

Embodiment #36. The system of Embodiment #33, wherein the second shapecomprises a rectangular section disposed across the bend axis and afirst semi-circular section disposed at an end of the rectangularsection on a first side of the bend axis and a semi-second circularsection disposed at an opposite end of the rectangular section and on anopposite side of the bend axis.

Embodiment #37. The system of Embodiment #32, wherein a first pluralityof cut-outs of the plurality of cut-outs are located near an approximatemid-point of a battery cell module.

Embodiment #38. The system of Embodiment #32, wherein a portion of theplurality of cut-outs is disposed on a bend line that is perpendicularto the bend axis and between two adjacent battery cell modules

Embodiment #39. A flexible printed circuit board assembly (PCBA)comprising:

a plurality of battery modules physically affixed to the flexible PCBA,wherein the plurality of battery modules is arranged in a grid-likepattern;

a bend axis near an approximate mid-point of the flexible PCBA, whereinbending the flexible PCBA along the bend axis results in a foldedconfiguration of the flexible PCBA; and

a plurality of cut-outs disposed along the bend axis, wherein theplurality of cut-outs reduces a force exerted on the flexible PCBA alongthe bend axis when the flexible circuit board is flexed.

Embodiment #40. The flexible PCBA of Embodiment #39, wherein theplurality of cut-outs disposed along the bend axis comprise a pluralityof first cut-outs having a first shape and a plurality of secondcut-outs having a second shape and wherein the plurality of firstcut-outs are disposed along a flexible portion of the flexible PCBAbetween adjacent rows of the grid-like pattern that are perpendicular tothe bend axis and the plurality of second cut-outs are disposed betweenadjacent battery modules in columns of the grid-like pattern, whereinthe columns are on opposite sides of the bend axis.

Embodiment #41. A conformal wearable battery comprising:

a plurality of battery cells arranged in a grid-like pattern, whereinthe plurality of battery cells includes a positive terminal and anegative terminal to provide electricity through a transfer of electronsbetween the positive terminal and negative terminal; and

a housing that includes:

-   -   a first shell formed from a first member having a first        plurality of rigid regions and a second member that has a first        flexible region located between a first rigid region and a        second rigid region of the first plurality of rigid regions, and        wherein the first shell includes a front wall with an outward        facing surface formed from outward facing surfaces of the first        plurality of rigid regions and an outward facing surface of the        second member, and    -   a second shell attached to the first shell, wherein the second        shell includes a third member having a second plurality of rigid        regions and a fourth member that has a second flexible region        located between a first rigid region and a second rigid region        of the second plurality of rigid regions, and wherein the second        shell has an outward facing surface formed from outward facing        surfaces of the second plurality of rigid regions and an outward        facing surface of the second member; and

wherein the first shell connects to the second shell to form an interiorcavity that receives the plurality of battery cells.

Embodiment #42. The conformal wearable battery of Embodiment #41,wherein the first member is formed from a first material and the secondmember is formed from a second material, wherein the first material hasa hardness that is greater than a hardness of the second material.

Embodiment #43. The conformal wearable battery of Embodiment #42,wherein the third member is formed from the first material and thefourth member is formed from the second material.

Embodiment #44. The conformal wearable battery of Embodiment #43,wherein the first material comprises a polycarbonate, and the secondmaterial comprises a thermoplastic elastomer.

Embodiment #45. The conformal wearable battery of Embodiment #41,wherein the second member is molded onto the first member to form thefirst shell.

Embodiment #46. The conformal wearable battery of Embodiment #41,wherein the first rigid region of the first plurality of rigid regionsincludes a first outward facing surface, a first inward facing surface,and a first edge region along a majority of a perimeter of the firstrigid region extending between the first outward facing surface and thefirst inward facing surface.

Embodiment #47. The conformal wearable battery of Embodiment #46,wherein the first edge region includes a first edge surface and a secondedge surface, wherein the first edge surface and the second edge surfaceextend in different directions.

Embodiment #48. The conformal wearable battery of Embodiment #47,wherein the second member has a second edge region that has acomplementary structure to the first edge region such that the firstmember and the second member are substantially coplanar on adjacentsurfaces of the first edge region.

Embodiment #49. A housing for a plurality of battery cells arranged in agrid-like pattern, the housing comprising:

a first shell having a first member having a plurality of rigid regionsand a second member that has a flexible region located between a firstrigid region and a second rigid region of the plurality of rigidregions, and wherein a first wall of the first shell has an outwardfacing surface formed from outward facing surfaces of the plurality ofrigid regions and an outward facing surface of the second member,

a second shell attached to the first shell forming an interior cavitybetween the first shell and the second shell,

wherein the first member is formed as a unitary member and the secondmember is molded onto the first member, and

wherein the first member is formed from a first material and the secondmember is formed from a second material, wherein the first materialhaving a first hardness and the second material has a second hardness,wherein the first hardness is greater than the second hardness.

Embodiment #50. The housing of Embodiment #49, wherein the plurality ofrigid regions are arranged in an array with the plurality of rigidregions in both a horizontal direction and a vertical direction thatcorrespond to the grid-like pattern of the plurality of battery cells.

Embodiment #51. The housing of Embodiment #49, wherein each rigid regionof the plurality of rigid regions are spaced apart from an adjacentrigid region and is connected to the adjacent rigid region by a channel.

Embodiment #52. The housing of Embodiment #51, wherein the channel actsas a living hinge.

Embodiment #53. The housing of Embodiment #51, wherein the channel has athickness that is less than a thickness of the first rigid region.

Embodiment #54. The housing of Embodiment #49, wherein the first rigidregion of the plurality of rigid regions includes a first outward facingsurface, a first inward facing surface, and a first edge region along amajority of a perimeter of the first rigid region extending between thefirst outward facing surface and the first inward facing surface.

Embodiment #55. The housing of Embodiment #54, wherein the first edgeregion includes a first edge surface that extends substantiallyperpendicular to the first outward facing surface and a second edgesurface has a portion that extends substantially perpendicular to thefirst edge surface.

Embodiment #56. The housing of Embodiment #55, wherein the second edgesurface includes a curved portion.

Embodiment #57. The housing of Embodiment #49, wherein a thickness ofthe first rigid region is substantially the same as a thickness of theflexible region, wherein the thickness of the first rigid region ismeasured at a center of the first rigid region and the thickness of theflexible region is measured at a location adjacent a first edge regionof the first rigid region.

Embodiment #58. The housing of Embodiment #49, wherein the second shellincludes a third member having a second plurality of rigid regions and afourth member that has a second flexible region located between a firstrigid region and a second rigid region of the second plurality of rigidregions, and wherein a first wall of the second shell has an outwardfacing surface formed from outward facing surfaces of the plurality ofrigid regions and an outward facing surface of the second member.

Embodiment #59. The housing of Embodiment #49, wherein the second memberincludes a plurality of horizontal grooves and a plurality of verticalgrooves.

Embodiment #60. A housing for a plurality of battery cells arranged in agrid-like pattern, the housing comprising:

a first shell having a first member having a plurality of rigid regionsand a second member that has a flexible region located between a firstrigid region and a second rigid region of the plurality of rigidregions, and wherein a first wall of the first shell has an outwardfacing surface formed from outward facing surfaces of the plurality ofrigid regions and an outward facing surface of the second member,wherein the plurality of rigid regions are arranged in an array with theplurality of rigid regions in both a horizontal direction and a verticaldirection that correspond to the grid-like pattern of the plurality ofbattery cells and each rigid region of the plurality of rigid regionsare spaced apart from an adjacent rigid region and is connected to theadjacent rigid region by a channel,

wherein the first member is formed as a unitary member and the secondmember is molded onto the first member, and

wherein the first member is formed from a first material and the secondmember is formed from a second material, wherein the first materialhaving a first hardness and the second material has a second hardness,wherein the first hardness is greater than the second hardness.

Embodiment #61. A conformal wearable battery comprising:

a plurality of non-cylindrical shaped polymer battery cells; and

a flexible printed circuit board (PCB) comprising:

-   -   a plurality of physical connection sections disposed in a grid        like pattern, wherein each of the plurality of battery cells is        physically affixed to the flexible PCB at a corresponding        physical connection section of the plurality of physical        connection sections; and    -   a bend axis that facilitates folding of the flexible PCB to form        an upper portion of the flexible PCB and a lower portion of the        flexible PCB;

a visco-elastic central shock-absorbing member positioned between theupper portion and the lower portion of the flexible PCB preventing theupper portion from contacting the lower portion, wherein the centralshock-absorbing member electrically insulates the upper portion from thelower portion; and

a flexible housing that includes an internal cavity that receives theplurality of battery cells, the flexible PCB, and the centralshock-absorbing member.

Embodiment #62. The conformal wearable battery of Embodiment #61,further comprising:

a plurality of visco-elastic battery cell shock-absorbing members, eachbattery cell shock-absorbing member of the plurality of battery cellshock-absorbing members being individually attached to an outward facingsurface of each battery cell, wherein each battery cell shock-absorbingmember has an opening that is substantially aligned with a center of apouch cell portion of each battery cell.

Embodiment #63. The conformal wearable battery of Embodiment #62,wherein the opening has an area that is within a range of 30 percent and70 percent of an area of a front surface of the battery cellshock-absorbing member, wherein the area of the front surface is definedas the area of the front surface that is free of the opening.

Embodiment #64. The conformal wearable battery of Embodiment #62,wherein at least one battery cell shock-absorbing member of theplurality of battery cell shock-absorbing members contacts an interiorsurface of the housing.

Embodiment #65. The conformal wearable battery of Embodiment #62,wherein a thickness of the central shock-absorbing member issubstantially the same as a thickness of one of the plurality of batterycell shock-absorbing members.

Embodiment #66. The conformal wearable battery of Embodiment #62,wherein a thickness of the central shock-absorbing member is within arange of 1.2 and 1.4 times a thickness of one of the plurality ofbattery cell shock-absorbing members.

Embodiment #67. The conformal wearable battery of Embodiment #61,wherein the central shock-absorbing member is continuous and extends atleast 90 percent of a width of the upper portion of the flexible PCB.

Embodiment #68. The conformal wearable battery of Embodiment #61,wherein a thickness of the central shock-absorbing member is within arange of 2 percent and 5 percent of a thickness of the conformalwearable battery, wherein the thickness of the conformal wearablebattery is a distance from an outermost outward facing surface of anupper housing member to an outermost outward facing surface of a lowerhousing member.

Embodiment #69. The conformal wearable battery of Embodiment #62,wherein the central shock-absorbing member is the same material as abattery cell shock-absorbing member of the plurality of battery cellshock-absorbing members, and wherein the central shock-absorbing membercomprises polyurethane.

Embodiment #70. A conformal wearable battery comprising:

a plurality of battery cells; and

a flexible printed circuit board (PCB) comprising:

a plurality of physical connection sections, wherein each of theplurality of battery cells is physically affixed to the flexible PCB ata corresponding physical connection section of the plurality of physicalconnection sections;

a bend axis that facilitates folding of the flexible PCB to form anupper portion of the flexible PCB and a lower portion of the flexiblePCB;

a plurality of battery cell shock-attenuating members, each battery cellshock-attenuating member of the plurality of battery cellshock-attenuating members being individually attached to an outwardfacing surface of each battery cell, wherein each battery cellshock-attenuating member is a foam member and has an opening thatextends through the battery cell shock-attenuating member; and

a housing that includes an upper housing member, a lower housing member,and an internal cavity, wherein the internal cavity that receives theplurality of battery cells, the flexible PCB, and the plurality ofbattery cell shock-attenuating members,

wherein a first battery cell shock-attenuating member of the pluralityof battery cell shock-attenuating members contacts an interior surfaceof the lower housing member and a second battery cell shock-attenuatingmember of the plurality of battery cell shock-attenuating memberscontacts an interior surface of the upper housing member.

Embodiment #71. The conformal wearable battery of Embodiment #70,wherein when a battery cell of the plurality of battery cells increasesin volume, one of a battery cell shock-attenuating member of theplurality of shock-attenuating members is compressed.

Embodiment #72. The conformal wearable battery of Embodiment #70,wherein a thickness of a battery cell shock-attenuating member of theplurality of battery cell shock-attenuating members is within a range of4 percent and 12 percent of a thickness of a battery cell of theplurality of battery cells.

Embodiment #73. The conformal wearable battery of Embodiment #70,wherein the opening of the plurality of battery cell shock-attenuatingmembers has an oval shape.

Embodiment #74. The conformal wearable battery of Embodiment #70,further comprising:

a central shock-attenuating member, the central shock-attenuating memberpositioned between the upper portion and the lower portion of theflexible PCB preventing the upper portion from contacting the lowerportion, wherein the central shock-attenuating member electricallyinsulates the upper portion from the lower portion.

Embodiment #75. The conformal wearable battery of Embodiment #74,wherein a thickness of the central shock-attenuating member issubstantially the same as a thickness of a battery cellshock-attenuating member of the plurality of battery cellshock-attenuating members.

Embodiment #76. A system comprising:

a plurality of battery cells; and

a flexible printed circuit board (PCB) comprising:

-   -   a plurality of physical connection sections, wherein each of the        plurality of battery cells is physically affixed to the flexible        PCB at a corresponding physical connection section of the        plurality of physical connection sections;    -   a bend axis that facilitates folding of the flexible PCB to form        an upper portion of the flexible PCB and a lower portion of the        flexible PCB;    -   a central shock-attenuating member formed from a polymeric foam        material, the central shock-attenuating member positioned        between the upper portion and the lower portion preventing the        upper portion of the flexible PCB from contacting the lower        portion of the flexible PCB;    -   a plurality of battery cell shock-attenuating members formed        from a polymeric foam material, each battery cell        shock-attenuating member of the plurality of battery cell        shock-attenuating members being individually attached to an        outward facing surface of each battery cell of the plurality of        battery cells; and    -   a housing that includes an internal cavity, wherein the internal        cavity receives the plurality of battery cells, the flexible        PCB, the central shock-attenuating member, and the plurality of        battery cell shock-attenuating members, wherein a battery cell        shock-attenuating member of the plurality of battery cell        shock-attenuating members contacts an interior surface of the        housing.

Embodiment #77. The system of Embodiment #76, wherein when a batterycell of the plurality of battery cells increases in volume, one of abattery cell shock-attenuating member of the plurality ofshock-attenuating members or the central shock-attenuating member iscompressed.

Embodiment #78. The system of Embodiment #76, wherein when a batterycell of the plurality of battery cells increases in volume, the batterycell that increases in volume expands into a cavity formed by an openingin each battery cell shock-attenuating member of the plurality ofbattery cell shock-attenuating members.

Embodiment #79. The system of Embodiment #76, wherein a thickness of abattery cell shock-attenuating member of the plurality of battery cellshock-attenuating members is within a range of 4 percent and 12 percentof a thickness of a battery cell of the plurality of battery cells.

Embodiment #80. The system of Embodiment #76, wherein the centralshock-attenuating member contacts both inward facing surfaces of theupper portion and the lower portion of the flexible PCB.

Embodiment #81. A conformal wearable battery comprising:

a plurality of battery cells, each battery cell including a pair ofelectrically conductive elements that correspond to either a cathode oran anode of each battery cell; and

a flexible printed circuit board (PCB) comprising:

-   -   a plurality of physical connection sections disposed in a grid        like pattern on a first side of the flexible PCB, wherein each        of the plurality of battery cells is disposed at a corresponding        physical connection section of the plurality of physical        connection sections;    -   a plurality of electrical connection pads linearly disposed on a        second side opposite the first side of the flexible PCB, the        plurality of electrical connection pads comprising an        electrically conductive surface coating; and

wherein the pair of electrically conductive elements extendsubstantially parallel to and along the second side of the flexible PCB,and wherein each electrically conductive elements are connected to acorresponding electrical connection pad of the plurality of electricalconnection pads on the second side of the flexible PCB forming anelectrical connection.

Embodiment #82. The conformal wearable battery of Embodiment #81,wherein the plurality of battery cells comprise pouch cell packagedpolymer lithium-ion, and each battery cell of the plurality of batterycells is physically attached to the first side of the flexible PCB.

Embodiment #83. The conformal wearable battery of Embodiment #81,wherein the flexible PCB further comprises:

a plurality of cutouts extending through the flexible PCB, wherein atleast one cutout of the plurality of cutouts is located adjacent to anelectrical connection pad of the plurality of electrical connectionpads.

Embodiment #84. The conformal wearable battery of Embodiment #83,wherein each conductive element of the pair of electrically conductiveelements extends through a corresponding cutout of the plurality ofcutouts.

Embodiment #85. The conformal wearable battery of Embodiment #81,wherein the electrically conductive surface coating comprises anelectroless nickel immersion gold (ENIG) surface coating.

Embodiment #86. The conformal wearable battery of Embodiment #81,wherein the electrically conductive surface coating comprises alead-free immersion silver surface coating.

Embodiment #87. The conformal wearable battery of Embodiment #81,wherein the electrical connection between each electrically conductiveelement of the pair of electrically conductive elements and thecorresponding electrical connection pad of the plurality of electricalconnection pads are joined with a weld.

Embodiment #88. The conformal wearable battery of Embodiment #87,wherein the weld is formed using a laser welding process.

Embodiment #89. The conformal wearable battery of Embodiment #87,wherein the weld is formed using an ultrasonic welding process.

Embodiment #90. The conformal wearable battery of Embodiment #81,wherein a connection pad of the plurality of electrical connection padshas a width that is within a range of 1.8 times and 3 times a width ofan electrically conductive element of the pair of electricallyconductive elements.

Embodiment #91. The conformal wearable battery of Embodiment #81,wherein a height electrical connection is within a range of 1.2 to 3times a thickness of an electrically conductive element of the pair ofelectrically conductive elements.

Embodiment #92. A system comprising:

a first plurality of battery cells; wherein a first battery cell of thefirst plurality of battery cell includes a first pair of electricallyconductive elements;

a second plurality of battery cells, wherein a second battery cell ofthe second plurality of battery cell includes a second pair ofelectrically conductive elements; and

a flexible printed circuit board (PCB) comprising:

-   -   a plurality of battery cell connection sections disposed in a        grid-like pattern along a first surface of the flexible PCB;    -   a plurality of cutouts disposed adjacent and parallel to an edge        of the plurality of battery cell connection sections, wherein        the plurality of cutouts is arranged as multiple pairs of        cutouts arranged adjacent a majority of the plurality of battery        cell connection sections; and    -   a plurality of electrical connection pads disposed on a second        surface of the flexible PCB opposite the first surface, wherein        a majority of the plurality of electrical connection pads are        arranged adjacent the plurality of cutouts, wherein the        plurality of electrical connection pads comprise an electrically        conductive surface coating;

wherein an electrically conductive element of the first pair ofelectrically conductive elements wraps around an edge of the flexiblePCB and extends along the second surface of the flexible PCB, whereinthe electrically conductive element of the first pair of electricallyconductive elements connects to a corresponding electrical connectionpad of the plurality of electrical connection pads forming a firstelectrical connection; and

wherein an electrically conductive element of the second pair ofelectrically conductive elements extends through a cutout of theplurality of cutouts, wherein each electrically conductive element ofthe second pair of electrically conductive elements connects to acorresponding electrical connection pad of the plurality electricalconnection pads forming a second electrical connection.

Embodiment #93. The system of Embodiment #92, wherein the firstelectrical connection between the electrically conductive element of thefirst pair of electrically conductive elements and the correspondingelectrical connection pad of the plurality of electrical connection padsare joined with a weld.

Embodiment #94. The system of Embodiment #93, wherein the weld is formedusing a laser welding process.

Embodiment #95. The system of Embodiment #94, wherein the weld is formedusing an ultrasonic welding process.

Embodiment #96. The system of Embodiment #92, wherein a connection padof the plurality of electrical connection pads has a circular shape witha diameter that is within a range of 1.8 times and 3 times a width of anelectrically conductive element of the first pair of electricallyconductive elements.

Embodiment #97. A flexible printed circuit board assembly (PCBA)comprising:

a flexible printed circuit board (PCB) comprising:

-   -   a first side;    -   a second side opposite the first side;    -   a plurality of electrical connection pads disposed on the second        side of the flexible PCB, the plurality of electrical connection        pads arranged in multiple pairs of electrical connection pads        and the plurality of electrical connection pads comprising an        electrically conductive surface coating;    -   a plurality of cutouts linearly disposed in the flexible PCB and        adjacent to corresponding electrical connection pads; and

a plurality of battery cell modules physically affixed to the first sideof the flexible PCB, wherein the plurality of battery cell modules arearranged in a grid-like pattern and comprise pouch cell packaged polymerlithium-ion, wherein each battery cell module of the plurality ofbattery cell modules includes a pair of electrically conductive elementsthat extend substantially parallel to the second side of the flexiblePCB and connect to corresponding electrical connection pads of theplurality of electrical connection pads forming an electrical connectionfor each battery cell module.

Embodiment #98. The flexible printed circuit board assembly (PCBA) ofEmbodiment #97, wherein the electrical connection between eachelectrically conductive elements of the pair of electrically conductiveelements and the corresponding electrical connection pads of theplurality of electrical connection pads are joined with a weld.

Embodiment #99. The flexible printed circuit board assembly (PCBA) ofEmbodiment #97, wherein a connection pad of the plurality of electricalconnection pads has a circular shape with a diameter that is within arange of 1.8 times and 3 times a width of an electrically conductiveelement of the pair of electrically conductive elements.

Embodiment #100. The flexible printed circuit board assembly (PCBA) ofEmbodiment #97, wherein each electrical connection pad of the pluralityof electrical connection pads comprises an electroless nickel immersiongold (ENIG) surface coating.

Embodiment #101. The system of Embodiment #92, wherein the firstplurality of battery cells and the second plurality of battery cellscomprise pouch cell packaged polymer lithium-ion.

Embodiment #102. The system of Embodiment #92, wherein the electricallyconductive surface coating comprises an electroless nickel immersiongold (ENIG) surface coating.

Embodiment #103. The system of Embodiment #92, wherein the electricallyconductive surface coating comprises a lead-free immersion silversurface coating.

Embodiment #104. The system of Embodiment #92, wherein a first height ofthe first electrical connection is within a range of 1.2 to 3 times athickness of a first electrically conductive element of the first pairof electrically conductive elements and a second height of the secondelectrical connection is within a range of 1.2 to 3 times a thickness ofa second electrically conductive element of the second pair ofelectrically conductive elements.

Embodiment #105. A conformal wearable battery comprising:

a first plurality of battery cells; wherein a first battery cell of thefirst plurality of battery cells includes a first pair of electricallyconductive elements;

a second plurality of battery cells, wherein a second battery cell ofthe second plurality of battery cells includes a second pair ofelectrically conductive elements, wherein the first plurality of batterycells and the second plurality of battery cells comprise pouch cellpackaged polymer lithium-ion; and

a flexible printed circuit board (PCB) comprising:

-   -   a plurality of battery cell connection sections disposed in a        grid-like pattern along a first surface of the flexible PCB;    -   a plurality of cutouts disposed adjacent and parallel to an edge        of the plurality of battery cell connection sections, wherein        the plurality of cutouts is arranged as multiple pairs of        cutouts arranged adjacent a majority of the plurality of battery        cell connection sections; and    -   a plurality of electrical connection pads disposed on a second        surface of the flexible PCB opposite the first surface, wherein        a majority of the plurality of electrical connection pads are        arranged adjacent the plurality of cutouts, wherein the        plurality of electrical connection pads comprise an electrically        conductive surface coating;    -   wherein an electrically conductive element of the first pair of        electrically conductive elements wraps around an edge of the        flexible PCB and extends along the second surface of the        flexible PCB, wherein the electrically conductive element of the        first pair of electrically conductive elements connects to a        corresponding electrical connection pad of the plurality of        electrical connection pads forming a first electrical        connection;    -   wherein an electrically conductive element of the second pair of        electrically conductive elements extends through a cutout of the        plurality of cutouts, wherein each electrically conductive        element of the second pair of electrically conductive elements        connects to a corresponding electrical connection pad of the        plurality electrical connection pads forming a second electrical        connection; and    -   wherein a first height of the first electrical connection is        within a range of 1.2 to 3 times a thickness of a first        electrically conductive element of the first pair of        electrically conductive elements and a second height of the        second electrical connection is within a range of 1.2 to 3 times        a thickness of a second electrically conductive element of the        second pair of electrically conductive elements.

Embodiment #106. The conformal wearable battery of Embodiment #105,wherein the first electrical connection between the electricallyconductive element of the first pair of electrically conductive elementsand the corresponding electrical connection pad of the plurality ofelectrical connection pads are joined with a weld.

Embodiment #107. The conformal wearable battery of Embodiment #106,wherein the weld is formed using a laser welding process.

Embodiment #108. The conformal wearable battery of Embodiment #106,wherein the weld is formed using an ultrasonic welding process.

Embodiment #109. The conformal wearable battery of Embodiment #105,wherein a connection pad of the plurality of electrical connection padshas a circular shape with a diameter that is within a range of 1.8 timesand 3 times a width of an electrically conductive element of the pair ofelectrically conductive elements.

Embodiment #110. A flexible printed circuit board (PCB) assemblycomprising:

a first plurality of battery cells; wherein a first battery cell of thefirst plurality of battery cells includes a first pair of electricallyconductive elements;

a second plurality of battery cells, wherein a second battery cell ofthe second plurality of battery cells includes a second pair ofelectrically conductive elements; and

a flexible printed circuit board comprising:

a plurality of battery cell connection sections disposed in a grid-likepattern along a first surface of the flexible PCB;

a plurality of cutouts disposed adjacent and parallel to an edge of theplurality of battery cell connection sections, wherein the plurality ofcutouts is arranged as multiple pairs of cutouts arranged adjacent amajority of the plurality of battery cell connection sections; and

a plurality of electrical connection pads disposed on a second surfaceof the flexible PCB opposite the first surface, wherein a majority ofthe plurality of electrical connection pads are arranged adjacent theplurality of cutouts, wherein the plurality of electrical connectionpads comprise an electrically conductive surface coating comprising anelectroless nickel immersion gold (ENIG) surface coating;

wherein an electrically conductive element of the first pair ofelectrically conductive elements wraps around an edge of the flexiblePCB and extends along the second surface of the flexible PCB, whereinthe electrically conductive element of the first pair of electricallyconductive elements connects, by a weld, to a corresponding electricalconnection pad of the plurality of electrical connection pads forming afirst electrical connection; and

wherein an electrically conductive element of the second pair ofelectrically conductive elements extends through a cutout of theplurality of cutouts, wherein each electrically conductive element ofthe second pair of electrically conductive elements connects to acorresponding electrical connection pad of the plurality electricalconnection pads forming a second electrical connection.

Embodiment #111. The flexible printed circuit board (PCB) assembly ofEmbodiment #110, wherein the first plurality of battery cells and thesecond plurality of battery cells comprise pouch cell packaged polymerlithium-ion.

Embodiment #112. The flexible printed circuit board (PCB) assembly ofEmbodiment #110, wherein the weld is formed using a laser weldingprocess.

Embodiment #113. The flexible printed circuit board (PCB) assembly ofEmbodiment #110, wherein the weld is formed using an ultrasonic weldingprocess.

Embodiment #114. The flexible printed circuit board (PCB) assembly ofEmbodiment #110, wherein a connection pad of the plurality of electricalconnection pads has a circular shape with a diameter that is within arange of 1.8 times and 3 times a width of an electrically conductiveelement of the pair of electrically conductive elements.

Embodiment #115. The flexible printed circuit board (PCB) assembly ofEmbodiment #110, wherein a first height of the first electricalconnection is within a range of 1.2 to 3 times a thickness of a firstelectrically conductive element of the first pair of electricallyconductive elements and a second height of the second electricalconnection is within a range of 1.2 to 3 times a thickness of a secondelectrically conductive element of the second pair of electricallyconductive elements.

Embodiment #116. A conformal wearable battery comprising:

a plurality of battery cells, each battery cell of the plurality ofbattery cells comprising:

-   -   a lithium-ion pouch cell; and    -   an attenuating member affixed to an exterior surface of the        lithium-ion pouch cell;

at least one circuitry module configured to control and monitor chargingand discharging of the plurality of battery cells; and

a flexible printed circuit board assembly (PCBA) comprising:

-   -   a plurality of physical connection sections disposed in a grid        like pattern, wherein each of the plurality of battery cells and        the at least one circuitry module is physically affixed to the        flexible PCBA at a corresponding physical connection section of        the plurality of physical connection sections;    -   a plurality of flexible regions distributed between the physical        connection sections disposed in the grid like pattern, wherein        the plurality of flexible regions allows the conformal wearable        battery to flex in response to an applied force; and    -   a plurality of electrical connection pad pairs, wherein each pad        pair of the plurality of electrical connection pad pairs is        associated with a corresponding physical connection section and        is positioned parallel to a corresponding flexible region.

Embodiment #117. The conformal wearable battery of Embodiment #116,wherein the flexible PCBA comprises a first plurality of electricalconnections each connecting a cathode of a corresponding battery cell ofthe plurality of battery cells and second plurality of electricalconnections each connecting an anode of the corresponding battery cellof the plurality of battery cells to electrical conductors of theflexible printed circuit board assembly.

Embodiment #118. The conformal wearable battery of Embodiment #116,wherein the plurality of battery cells and the at least one circuitrymodule, when affixed to the flexible PCBA, comprises a matrix ofphysical components.

Embodiment #119. The conformal wearable battery of Embodiment #18wherein the matrix of physical components comprises a matrix of at leasttwo rows and at least two columns.

Embodiment #120. The conformal wearable battery of Embodiment #116,wherein conformal wearable battery comprises at least one connectorconfigured to provide an electrical power connection from internalcircuitry of the conformal wearable battery to an external device to bepowered.

Embodiment #121. The conformal wearable battery of Embodiment #120,wherein the plurality of battery cells, the at least one connector, andthe at least one circuitry module, when affixed to the flexible PCBA,comprises a matrix of physical components.

Embodiment #122. The conformal wearable battery of Embodiment #116,wherein a bend axis comprises a center of the grid like pattern of thephysical connection sections when the flexible PCBA is unfolded.

Embodiment #123. The conformal wearable battery of Embodiment #116,wherein each of the plurality of battery cells is physically attached toa first side of the flexible PCBA.

Embodiment #124. The conformal wearable battery of Embodiment #116,wherein each of the plurality of battery cells is physically attached toa first side of the flexible PCBA and each of the plurality of batterycells is electrically connected to the flexible PCBA on a second side ofthe flexible PCBA, the second side being opposite the first side.

Embodiment #125. The conformal wearable battery of Embodiment #116,wherein the plurality of battery cells is disposed on an outside surfaceof the flexible PCBA, when the flexible PCBA is in a foldedconfiguration.

Embodiment #126. The conformal wearable battery of Embodiment #125,wherein the plurality of battery cells is arranged in athree-dimensional grid pattern.

Embodiment #127. The conformal wearable battery of Embodiment #116,further comprising a sealed flexible housing wherein the flexible PCBAis disposed within an interior cavity of the sealed flexible housing andwherein the flexible PCBA is in a folded configuration.

Embodiment #128. A system comprising:

a plurality of battery cell modules, each battery cell module of theplurality of battery cell modules comprising:

-   -   a lithium-ion pouch cell comprising a cathode tab and an anode        tab;    -   an attenuating member affixed to an exterior surface of the        lithium-ion pouch cell;

a flexible printed circuit board assembly (PCBA) comprising:

-   -   a plurality of battery cell connection sections disposed in a        grid-like pattern along a first surface of the flexible PCBA;        and

a plurality of electrical connection pad pairs, wherein each pad pair ofthe plurality of pad pairs is associated with a corresponding batterycell connection section and is positioned parallel to a correspondingflexible region of the flexible PCBA, wherein each of the plurality ofbattery cell modules is electrically attached to the flexible PCBA on asecond surface of the flexible PCBA in a grid-like pattern via acorresponding pad pair, and wherein the second surface is opposite thefirst surface.

Embodiment #129. The system of Embodiment #128, further comprising ahousing, wherein the flexible PCBA, when in a folded configuration, islocated within the housing.

Embodiment #130. The system of Embodiment #128, wherein a center line ofthe attenuating member of each of the plurality of battery cell modulesis offset from a center line of the lithium-ion pouch cell.

Embodiment #131. The system of Embodiment #129, wherein the battery cellcomprises a lithium-ion battery cell.

Embodiment #132. The system of Embodiment #128, wherein the plurality ofbattery cell modules is arranged in a three-dimensional grid patternwhen the flexible PCBA is in a folded configuration.

Embodiment #133. A flexible printed circuit board assembly (PCBA)comprising:

a plurality of battery modules physically affixed to the flexible PCBA,wherein the plurality of battery modules is arranged in a grid-likepattern, wherein each battery module of the plurality of battery cellmodules comprises:

-   -   a lithium-ion pouch cell; and    -   an attenuating member affixed to an exterior surface of the        lithium-ion pouch cell;

a bend axis near an approximate mid-point of the flexible PCBA, whereinbending the flexible PCBA along the bend axis results in a foldedconfiguration of the flexible PCBA; wherein, when the flexible PCBA isin a folded configuration:

the plurality of battery modules is disposed in a flexiblethree-dimensional grid-like pattern on an exterior surface of the foldedflexible PCBA, and

the plurality of battery modules is electrically connected to theflexible PCBA via electrical pads disposed parallel and adjacent to aflexible section between adjacent rows of battery modules of thegrid-like pattern.

Embodiment #134. The flexible PCBA of Embodiment #133, furthercomprising a plurality of the flexible sections, wherein the pluralityof the flexible sections allows for the flexible PCBA to flex betweenadjacent rows and adjacent columns of battery modules.

Embodiment #135. A conformal wearable battery with a redundant tracefuse circuit, comprising:

a plurality of battery cells arranged in a grid-like pattern, whereineach battery cell of the plurality of battery cells comprise a positiveterminal and a negative terminal to provide electricity through atransfer of electrons between the positive terminal and negativeterminal;

a housing with an interior cavity that receives the plurality of batterycells;

a printed circuit board, comprising:

-   -   a first electrical connection pad coupled to a positive terminal        of a battery cell of the plurality of battery cells;    -   a positive conductive region receiving electrical energy via        positive terminals of one or more of the plurality of battery        cells; and    -   a first redundant trace fuse circuit comprising:        -   a first fusible link electrically connecting the first            electrical connection pad to the positive conductive region;            and        -   a second fusible link that is selectively enabled to            electrically connect the first electrical connection pad to            the positive conductive region.

Embodiment #136. The conformal wearable battery of Embodiment #135,wherein the printed circuit board comprises:

a second electrical connection pad coupled to a negative terminal of thebattery cell of the plurality of battery cells;

a negative conductive region receiving electrical energy via negativeterminals of one or more of the plurality of battery cells; and

a second redundant trace fuse circuit comprising:

-   -   a third fusible link electrically connecting the second        electrical connection pad to the negative conductive region; and    -   a fourth fusible link to selectively electrically connect the        second electrical connection pad to the negative conductive        region.

Embodiment #137. The conformal wearable battery of Embodiment #135,wherein the first redundant trace fuse circuit comprises a plurality ofconductive paths to connect the first electrical connection pad to thepositive conductive region, wherein each of the plurality of conductivepaths are connected independently from the other.

Embodiment #138. The conformal wearable battery of Embodiment #137,wherein a first conductive path of the plurality of conductive pathscomprises a fuse element and a first pair of electrically separatedconductive pads, wherein the fuse element is enabled via connection of ajumper between the first pair of electrically separated conductive pads.

Embodiment #139. The conformal wearable battery of Embodiment #137,wherein the printed circuit board comprises a flexible printed circuitboard and further comprises:

a plurality of physical connection sections disposed in a grid likepattern, wherein each of the plurality of battery cells and the at leastone circuitry module is physically affixed to the printed circuit boardat a corresponding physical connection section of the plurality ofphysical connection sections;

a plurality of flexible regions distributed between the physicalconnection sections disposed in the grid like pattern, wherein theplurality of flexible regions allows the conformal wearable battery toflex in response to an applied force;

a plurality of electrical connection pad pairs, wherein each pad pair ofthe plurality of electrical connection pad pairs comprises an adjacentpair of electrical connection pads that is associated with acorresponding physical connection section, and is aligned parallel to acorresponding flexible region, wherein the plurality of electricalconnection pad pairs comprises a first electrical connection pad pairand a second electrical connection pad pair and wherein the firstelectrical connection pad pair comprises the first electrical connectionpad;

a pair of cutouts in the flexible PCBA through which a first pair ofelectrically conductive elements of the first battery cell extend,wherein the first pair of electrically conductive elements of the firstbattery cell are electrically connected to the first electricalconnection pad pair; and

an edge of the flexible PCBA around which a second pair of electricallyconductive elements of the second battery cell wraps, wherein the secondpair of electrically conductive elements of the second battery cell areelectrically connected to adjacent pads of the second electricalconnection pad pair.

Embodiment #140. A printed circuit board, comprising:

a pair of electrical connection pads, wherein a first electricalconnection pad is coupled to a positive terminal of a battery cell of aplurality of battery cells and a second electrical connection pad iscoupled to a negative terminal of the battery cell of the plurality ofbattery cells;

a positive conductive region receiving electrical energy via positiveterminals of one or more of the plurality of battery cells;

a negative conductive region receiving electrical energy via negativeterminals of one or more of the plurality of battery cells; and

a plurality of first redundant trace fuse circuits, wherein each tracefuse circuit comprises:

-   -   a first fusible link that electrically connects the first        electrical connection pad to the positive conductive region; and    -   a second fusible link that is selectively enabled to        electrically connect the first electrical connection pad to the        positive conductive region.

Embodiment #141. The printed circuit board of Embodiment #140,comprising:

a second redundant trace fuse circuit comprising:

-   -   a third fusible link electrically connecting the second        electrical connection pad to the negative conductive region; and    -   a fourth fusible link to selectively electrically connect the        second electrical connection pad to the negative conductive        region.

Embodiment #142. The printed circuit board of Embodiment #140, whereinthe second fusible link comprises a plurality of conductive paths toconnect the first electrical connection pad to the positive conductiveregion, wherein each of the plurality of conductive paths are connectedindependently from the other.

Embodiment #143. The printed circuit board of Embodiment #142, wherein afirst conductive path of the plurality of conductive paths comprises afuse element and a first pair of electrically separated conductive pads,wherein the fuse element is enabled via connection of a jumper betweenthe first pair of electrically separated conductive pads.

Embodiment #144. The printed circuit board of Embodiment #142, whereinat a first conductive path of the plurality of conductive paths comprisea pair of electrically separated conductive pads, wherein the firstconductive path is enabled via connection of an external fuse component.

Embodiment #145. A method comprising:

forming a first electrical connection between a first electricalconnection pad and a first battery terminal;

measuring, after forming the first electrical connection, continuity ofa first electrical path between the first electrical connection pad anda first conductive region of a printed circuit board, wherein the firstelectrical path comprises a first trace fuse component formed on theprinted circuit board;

selectively enabling, based on a measured discontinuity in the firstelectrical path, a second electrical connection between the firstelectrical connection pad and the first conductive region, wherein thesecond electrical connection comprises a second fuse component.

Embodiment #146. The method of Embodiment #145, wherein forming thesecond electrical connection path comprises electrically connecting asecond fuse component using a conductive shunt component.

Embodiment #147. The method of Embodiment #145, wherein the second fusecomponent comprises a second trace fuse component formed on the printedcircuit board.

Embodiment #148. The method of Embodiment #145, comprising:

measuring, after forming the second electrical connection, continuity ofa second electrical path between the first electrical connection pad andthe first conductive region of the printed circuit board, wherein thesecond electrical path comprises a second trace fuse component formed onthe printed circuit board;

selectively enabling, based on a measured discontinuity in the secondelectrical path, a third electrical path between the first electricalconnection pad and the first conductive region, wherein the thirdelectrical path comprises a third fuse component

Embodiment #149. The method of Embodiment #148, wherein the third fusecomponent comprises one of a third trace fuse component or a pair ofsecondary electrical connection pads formed on the printed circuit boardto receive an external fuse component.

Embodiment #150. The method of Embodiment #145, wherein the second fusecomponent comprises electrically connecting a fuse component to a pairof secondary electrical connection pads formed on the printed circuitboard.

Embodiment #151. The method of Embodiment #145, wherein forming thefirst electrical connection between the first electrical connection padand the first battery terminal comprises heating one or both of thefirst electrical connection pad and the first battery terminal andwherein the heating one or both of the first electrical connection padand the first battery terminal causes the discontinuity in the firstelectrical path.

Embodiment #152. The method of Embodiment #145, further comprising:

inserting through a pair of cutouts in the printed circuit board, thefirst battery terminal and a second battery terminal of a first batterycell, wherein the first battery cell is positioned adjacent a first sideof the printed circuit board and the first electrical connection pad anda second electrical connection pad are on a second side of the printedcircuit board opposite the first side;

forming a second electrical connection between a second electricalconnection pad and the second battery terminal;

measuring, after forming the second electrical connection, continuity ofa fourth electrical path between the second electrical connection padand a second conductive region of a printed circuit board, wherein thesecond electrical path comprises a fourth trace fuse component formed onthe printed circuit board;

selectively enabling, based on a measured discontinuity in the fourthelectrical path, a fifth electrical connection between the secondelectrical connection pad and the second conductive region, wherein thefifth electrical connection comprises a fifth fuse component.

Embodiment #153. The method of Embodiment #152, further comprising:

connecting, based on a successful connection of the first battery cellto the printed circuit board, a second battery cell to the printedcircuit board by:

-   -   forming a sixth electrical connection between a third electrical        connection pad and a third battery terminal comprising an anode        of the second battery cell;    -   measuring, after forming the sixth electrical connection,        continuity of a sixth electrical path between the third        electrical connection pad and a first conductive region of a        printed circuit board, wherein the sixth electrical path        comprises a sixth trace fuse component formed on the printed        circuit board;    -   selectively enabling, based on a measured discontinuity in the        third electrical path, a seventh electrical connection between        the third electrical connection pad and the first conductive        region, wherein the seventh electrical connection comprises a        seventh fuse component.

Embodiment #154. A method of assembling a printed circuit board assemblycomprising:

(a) electrically connecting, via an application of heat energy, an anodetab of a battery cell to a first electrical connection pad formed in aprinted circuit board and a cathode tab of the battery cell to a secondelectrical connection pad formed in the printed circuit board, whereinthe first electrical connection pad is electrically connected to a firstcharge bus of the printed circuit board via a first trace fuse of afirst redundant trace fuse assembly and the second electrical connectionpad is electrically connected to a second charge bus of the printedcircuit board via a second trace fuse of a second redundant trace fuseassembly and wherein the first trace fuse assembly and the second tracefuse assembly are formed in the printed circuit board;

(b) determining whether one of the first trace fuse or the second tracefuse is in open circuit condition;

(c) selectively enabling, based on an indication that the first tracefuse is an open circuit condition, a third trace fuse of the first tracefuse assembly;

(d) selectively enabling, based on an indication that the second tracefuse is an open circuit condition, a fourth trace fuse of the secondtrace fuse assembly;

(e) determining whether one of the third trace fuse or the fourth tracefuse is in open circuit condition;

(f) repeating steps (a)-(e), based on an indication that the anode tabis electrically connected to the first charge bus via the firstredundant trace fuse assembly and the cathode tab is electricallyconnected to the second charge bus via the second redundant trace fuseassembly, to electrically connect a second battery cell to the printedcircuit board; and

(g) discontinuing, based on an indication that at least one of the thirdtrace fuse or the fourth trace fuse is in an open circuit condition,assembly of the printed circuit board assembly.

What is claimed is:
 1. A conformal wearable battery with a redundanttrace fuse circuit, comprising: a plurality of battery cells arranged ina grid-like pattern, wherein each battery cell of the plurality ofbattery cells comprise a positive terminal and a negative terminal toprovide electricity through a transfer of electrons between the positiveterminal and negative terminal; a housing with an interior cavity thatreceives the plurality of battery cells; a printed circuit board,comprising: a first electrical connection pad coupled to a positiveterminal of a battery cell of the plurality of battery cells; a positiveconductive region receiving electrical energy via positive terminals ofone or more of the plurality of battery cells; and a first redundanttrace fuse circuit comprising: a first fusible link electricallyconnecting the first electrical connection pad to the positiveconductive region, wherein the first fusible link is integral to theprinted circuit board such that the first fusible link is irreparableonce blown; and a second fusible link that is selectively enabled toelectrically connect the first electrical connection pad to the positiveconductive region.
 2. The conformal wearable battery of claim 1, whereinthe printed circuit board comprises: a second electrical connection padcoupled to a negative terminal of the battery cell of the plurality ofbattery cells; a negative conductive region receiving electrical energyvia negative terminals of one or more of the plurality of battery cells;and a second redundant trace fuse circuit comprising: a third fusiblelink electrically connecting the second electrical connection pad to thenegative conductive region; and a fourth fusible link to selectivelyelectrically connect the second electrical connection pad to thenegative conductive region.
 3. The conformal wearable battery of claim1, wherein the first fusible link comprises a section of conductorconfigured to become inoperative after a current in excess of athreshold amount is passed to the section of conductor, wherein thefirst redundant trace fuse circuit comprises a plurality of conductivepaths to connect the first electrical connection pad to the positiveconductive region, and wherein each of the plurality of conductive pathsare connected independently from the other.
 4. The conformal wearablebattery of claim 3, wherein a first conductive path of the plurality ofconductive paths comprises a fuse element and a first pair ofelectrically separated conductive pads, wherein the fuse element isenabled via connection of a jumper between the first pair ofelectrically separated conductive pads.
 5. The conformal wearablebattery of claim 1, wherein the printed circuit board comprises aflexible printed circuit board and further comprises: a plurality ofphysical connection sections disposed in a grid like pattern, whereineach of the plurality of battery cells and the at least one circuitrymodule is physically affixed to the printed circuit board at acorresponding physical connection section of the plurality of physicalconnection sections; a plurality of flexible regions distributed betweenthe physical connection sections disposed in the grid like pattern,wherein the plurality of flexible regions allows the conformal wearablebattery to flex in response to an applied force; a plurality ofelectrical connection pad pairs, wherein each pad pair of the pluralityof electrical connection pad pairs comprises an adjacent pair ofelectrical connection pads that is associated with a correspondingphysical connection section, and is aligned parallel to a correspondingflexible region, wherein the plurality of electrical connection padpairs comprises a first electrical connection pad pair and a secondelectrical connection pad pair and wherein the first electricalconnection pad belongs to one of the first electrical pad pair or thesecond electrical pad pair; a pair of cutouts in the flexible printedcircuit board through which a first pair of electrically conductiveelements of the first battery cell extend, wherein the first pair ofelectrically conductive elements of the first battery cell areelectrically connected to the first electrical connection pad pair; andan edge of the flexible printed circuit board around which a second pairof electrically conductive elements of the second battery cell wraps,wherein the second pair of electrically conductive elements of thesecond battery cell are electrically connected to adjacent pads of thesecond electrical connection pad pair.
 6. A printed circuit board,comprising: a pair of electrical connection pads, wherein a firstelectrical connection pad is coupled to a positive terminal of a batterycell of a plurality of battery cells and a second electrical connectionpad is coupled to a negative terminal of the battery cell of theplurality of battery cells; a positive conductive region receivingelectrical energy via positive terminals of one or more of the pluralityof battery cells; a negative conductive region receiving electricalenergy via negative terminals of one or more of the plurality of batterycells; and a plurality of first redundant trace fuse circuits, whereineach trace fuse circuit comprises: a first fusible link thatelectrically connects the first electrical connection pad to thepositive conductive region; and a second fusible link that isselectively enabled to electrically connect the first electricalconnection pad to the positive conductive region.
 7. The printed circuitboard of claim 6, comprising: a second redundant trace fuse circuitcomprising: a third fusible link electrically connecting the secondelectrical connection pad to the negative conductive region; and afourth fusible link to selectively electrically connect the secondelectrical connection pad to the negative conductive region.
 8. Theprinted circuit board of claim 6, wherein the first fusible linkcomprises a section of conductor capable of transferring heat energyfrom first electrical connection pad to the section of conductor,wherein the second fusible link comprises a plurality of conductivepaths to connect the first electrical connection pad to the positiveconductive region, wherein each of the plurality of conductive paths areconnected independently from the other.
 9. The printed circuit board ofclaim 8, wherein a first conductive path of the plurality of conductivepaths comprises a fuse element and a first pair of electricallyseparated conductive pads, wherein the fuse element is enabled viaconnection of a jumper between the first pair of electrically separatedconductive pads.
 10. The printed circuit board of claim 8, wherein at afirst conductive path of the plurality of conductive paths comprise apair of electrically separated conductive pads, wherein the firstconductive path is enabled via connection of an external fuse component.11. A method comprising: forming a first electrical connection between afirst electrical connection pad and a first battery terminal by heatenergy applied to the first electrical connection pad; measuring, afterforming the first electrical connection, continuity of a firstelectrical path between the first electrical connection pad and a firstconductive region of a printed circuit board, wherein the firstelectrical path comprises a first trace fuse component formed on theprinted circuit board, wherein the first trace fuse component isintegrated to the printed circuit board such that the first trace fusecomponent is irreparable once melted by the heat energy; selectivelyenabling, based on a measured discontinuity in the first electricalpath, a second electrical connection between the first electricalconnection pad and the first conductive region, wherein the secondelectrical connection comprises a second fuse component.
 12. The methodof claim 11, wherein forming the second electrical connection pathcomprises electrically connecting a second fuse component using aconductive shunt component.
 13. The method of claim 12, wherein thesecond fuse component comprises a second trace fuse component formed onthe printed circuit board.
 14. The method of claim 11 comprising:measuring, after forming the second electrical connection, continuity ofa second electrical path between the first electrical connection pad andthe first conductive region of the printed circuit board, wherein thesecond electrical path comprises a second trace fuse component formed onthe printed circuit board; selectively enabling, based on a measureddiscontinuity in the second electrical path, a third electrical pathbetween the first electrical connection pad and the first conductiveregion, wherein the third electrical path comprises a third fusecomponent.
 15. The method of claim 11, wherein the second fuse componentcomprises electrically connecting a fuse component to a pair ofsecondary electrical connection pads formed on the printed circuitboard.
 16. The method of claim 11, wherein forming the first electricalconnection between the first electrical connection pad and the firstbattery terminal comprises heating one or both of the first electricalconnection pad and the first battery terminal and wherein the heatingone or both of the first electrical connection pad and the first batteryterminal causes the discontinuity in the first electrical path.
 17. Themethod of claim 11, further comprising: inserting through a pair ofcutouts in the printed circuit board, the first battery terminal and asecond battery terminal of a first battery cell, wherein the firstbattery cell is positioned adjacent a first side of the printed circuitboard and the first electrical connection pad and a second electricalconnection pad are on a second side of the printed circuit boardopposite the first side; forming a second electrical connection betweena second electrical connection pad and the second battery terminal;measuring, after forming the second electrical connection, continuity ofa fourth electrical path between the second electrical connection padand a second conductive region of a printed circuit board, wherein thesecond electrical path comprises a fourth trace fuse component formed onthe printed circuit board; selectively enabling, based on a measureddiscontinuity in the fourth electrical path, a fifth electricalconnection between the second electrical connection pad and the secondconductive region, wherein the fifth electrical connection comprises afifth fuse component.
 18. The method of claim 17, further comprising:connecting, based on a successful connection of the first battery cellto the printed circuit board, a second battery cell to the printedcircuit board by: forming a sixth electrical connection between a thirdelectrical connection pad and a third battery terminal comprising ananode of the second battery cell; measuring, after forming the sixthelectrical connection, continuity of a sixth electrical path between thethird electrical connection pad and a first conductive region of aprinted circuit board, wherein the sixth electrical path comprises asixth trace fuse component formed on the printed circuit board;selectively enabling, based on a measured discontinuity in the thirdelectrical path, a seventh electrical connection between the thirdelectrical connection pad and the first conductive region, wherein theseventh electrical connection comprises a seventh fuse component.
 19. Amethod of assembling a conformable wearable battery pack with a printedcircuit board assembly with a redundant trace fuse, the methodcomprising: (a) electrically connecting, via an application of heatenergy, a battery cell to a first electrical connection pad formed in aprinted circuit board, wherein the first electrical connection pad iselectrically connected to a charge bus of the printed circuit board viaa first trace fuse of the redundant trace fuse and wherein the firsttrace fuse is formed in the printed circuit board; (b) determining thatthe first trace fuse is in open circuit condition after the applicationof the heat energy; (c) selectively enabling, based on an indicationthat the first trace fuse is an open circuit condition, a second tracefuse of the redundant trace fuse by applying heat energy to a secondelectrical connection pad formed in the printed circuit board, whereinthe second electrical connection pad is electrically connected to thecharge bus of the printed circuit board via the second trace fuse; and(d) if the second trace fuse is determined to be operative after step(c), then continuing with assembly of the printed circuit boardassembly.
 20. The method of claim 19, further comprising: if the secondtrace fuse is determined to be inoperative after step (c), thendiscontinuing assembly of the printed circuit board assembly.